Facto

oryTalk Metrrics: Introducction Lab

For Claassroom Use

U Only!!
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FactoryTalk Metrics: Introduction Lab

Contents
Before you begin ........................................................................................................................................... 5
About this lab .................................................................................................................................................................................... 5
Tools & prerequisites ........................................................................................................................................................................ 7

Getting Started .............................................................................................................................................. 8

Updating the FTMetrics Database .................................................................................................................................................... 8
Starting the FactoryTalk View SE Project ....................................................................................................................................... 10
Open and Run the FactoryTalk View SE Project ............................................................................................................................ 10
Start Data Collection ....................................................................................................................................................................... 12
Production Simulation in FactoryTalk View SE ............................................................................................................................... 14

Lab Objectives ............................................................................................................................................ 18

Introduction to OEE......................................................................................................................................................................... 19

How well has the plant been performing? ................................................................................................... 20

What are some of the ways we can measure performance? .......................................................................................................... 25
What is the worst performing line?.................................................................................................................................................. 26
What is the worst performing machine?.......................................................................................................................................... 27
What is the worst performing shift?................................................................................................................................................. 34
What is the worst performing Part?................................................................................................................................................. 37
Who is the worst performing operator? ........................................................................................................................................... 39
Drill-Through and Exporting Report Data........................................................................................................................................ 41
What have we learned so far? ........................................................................................................................................................ 47

How can the plant’s performance be improved?......................................................................................... 48

How can we start reducing downtime (or lost time)? ...................................................................................................................... 49
Can machine speed be increased? ................................................................................................................................................ 74
Can Quality be increased?.............................................................................................................................................................. 76

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What is happening right now? ..................................................................................................................... 78

Using FactoryTalk VantagePoint EMI to visualize FactoryTalk Metrics data ............................................. 83

How do we get the right information to the right people? ........................................................................... 89

Summary ..................................................................................................................................................... 97

Appendix A – Report Template Columns and Drill-Through Destinations .................................................. 99

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Before you begin

FactoryTalk Metrics is a solution for optimizing production efficiency by monitoring equipment downtime causes, part counts,
bottlenecks, and other production events. For each work cell in your facility, FactoryTalk Metrics monitors Overall Equipment
Efficiency (OEE), which is a measure of availability, production rates, and quality. OEE is one of many key performance
indicators that FactoryTalk Metrics provides to help you evaluate your manufacturing performance.
FactoryTalk Metrics is not just an “OEE Product”. Its most powerful capabilities allow you to configure data collection and
reporting on production events of any kind, including but not limited to downtime events, with great detail and granularity. This
detailed data helps you identify the root cause of process inefficiencies and to prioritize improvement efforts for maximum impact.

About this lab

This lab focuses entirely on the Report Expert reporting environment that comes with FactoryTalk Metrics. The lab concentrates
on how to use the Report Expert user interface to perform ad-hoc reporting, and how to interpret the data the resulting data. It is
not intended to illustrate how a completed application might be delivered to an end customer. It is hoped that the user will gain
an appreciation for the data that is contained in a FactoryTalk Metrics application, and how Report Expert might be used to
analyze that data and to create a usable application for a customer.
The lab does not cover configuration of FactoryTalk Metrics, nor does it cover all of the features of Report Expert. These topics
are covered in other labs, and your instructor may be able to provide you with lab materials that cover that information.
This lab also does not attempt to cover SQL Server 2008 or Microsoft Reporting Services 2008 (MSRS) topics, although Report
Expert uses MSRS extensively. If you will be implementing or maintaining FactoryTalk Metrics systems, it is recommended that
you take Microsoft training on those two subjects.
The lab uses a FactoryTalk View SE project, together with SoftLogix, as its control system. FactoryTalk Metrics works with
virtually any control system, so the attributes of the control system are not important in learning the material in the lab, but some
interaction with View SE screens is necessary to produce “interesting” data for FactoryTalk Metrics to collect. The database on
the VMWare image contains some historical data which will be useful in showing the capabilities of Report Expert.
The Report Expert application contains all of the default content of a standard installation, and only “out-of-the-box” reports are
used in this lab. The image also contains some custom reports that were created using methods supported by Report Expert. It
is important to remember that the out-of-the-box content: reports, templates, explorer tree, etc. is meant only to be an illustration
of how Report Expert might be used in a very generic way. Report Expert is meant to be customized for a particular customer’s
application and reporting needs; and this lab is designed to expose you to the capabilities that will enable that customization.

This lab takes approximately 90 minutes to complete.

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This lab uses one VMWare image. The software installed on the image is detailed in the next section. Listed here is useful
information about the image that may be required during the course of the lab.

VMWare image name: Base-Server 2008 R2 Standard x64

Computer name: W2K8xPOC2
Windows Administrator username/password: Administrator/rockwell
FactoryTalk username/password: Admin/Admin
FactoryTalk Metrics administrator username/password: Administrator/rockwell
SQL Server login/password: Administrator (Windows authentication) or FTMUser/FTMUser (SQL Server Authentication)
SQL Server database name: FTMetrics
System DSN name: FTMetrics
FactoryTalk Transaction Manager configuration name: FTMetrics
Lab files location: C:\Lab Files\FactoryTalk Metrics Introduction Lab

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Tools & prerequisites
This lab uses the currently-shipping FactoryTalk Metrics 10.00, which includes Report Expert 2.20. It also uses FactoryTalk
VantagePoint EMI 4.0.
This lab utilizes one VMWare image using VMWare Workstation 8.0.2. The following software is installed on the image:

 Microsoft Windows Server 2008 R2 Standard Edition (64-bit)

 Microsoft Internet Explorer 8.0
 Microsoft SQL Server 2008 R2 Standard Edition
 Microsoft Reporting Services 2008 (included with SQL Server 2008 R2)
 RSBizWare 10.00 software, which includes FactoryTalk Metrics 10.00
 Report Expert 2.20
 FactoryTalk VantagePoint EMI 4.0
 Microsoft Office 2010
 FactoryTalk Services Platform 2.50.00 (CPR 9 SR5)
 FactoryTalk View SE version 6.10
 SoftLogix5800 version 20.00.00
 RSLogix 5000 version 20.00
 A configured FactoryTalk Metrics application and database
 A FactoryTalk View SE project called FTM
 An RSLogix 5000 program called FTMetrics.acd
 Activation licenses for appropriate software.

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Getting Started
S

Updating the
t FTMetricss Database
The FTMetrrics database, ass included on this image, containns several days of FactoryTalk M Metrics data thatt was collected in the
past. We want
w to take this datad and bring itt up to the currennt date, so we caan look at data pprior to that colleected during the lab
itself. To doo that, we will runn a stored proceedure called spU UpdateDatabase that has been aadded to the FTM Metrics databasee. This
script takes the data in the database
d in the past
p and changees the dates to thhe days immediately prior to thee current date. TThe
script is run during the lab because
b the resuults will be differeent on every dayy.

1. Run SQL
S Server 20008 Managemennt Studio. Starrt > All Prograams > Microsooft SQL Serverr 2008 R2 > SQ
QL
Server Managemen
nt Studio.
Microssoft SQL Serveer Management Studio will oppen. Click Connnect to connecct to the SQL S
Server instancee.

2. Selectt File > Open > File.

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3. Navigaate to C:\Lab Files\FactoryT
F Talk Metrics In
ntroduction\ annd open UpdatteDatabase.sqql.
Click the
t Execute buutton to executee the stored prrocedure. .

4. When it finishes, there will be messsages in the low

wer window, buut there shouldd be no errors ((which will be inn red
text). Close
C Microsofft SQL Server Management Studio
S

The FTMetrrics database noow contains seveeral days of histoorical data, endinng with yesterdaay. In the next seection we will beegin
FactoryTalkk Metrics data coollection, which will
w collect data foor the current tim
me.

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Starting th
he FactoryTalkk View SE Pro
oject
The image includes a FactooryTalk View SE project, a FactooryTalk Transacttion Manager daata collection connfiguration, and aan
RSLogix 5000 program runnning in a SoftLoggix controller. Thhis control system
m serves two puurposes:
 Thhere is a traditional HMI, displayying data in the controller,
c relayinng information about the runningg operations andd
prroviding an interfface mechanism m for controlling production.
p
 o a manufacturinng process, generating events foor starting/comppleting manufacturing operationss
It is a simulation of
(cchangeovers, etcc.) and for other system events (downtime,
( blockked, starved, etcc.). As such it is the source of daata for
FaactoryTalk Metrics.
Before you can examine FaactoryTalk Metriccs reports, you will
w start producti on in the simulaated factory by ruunning the FactooryTalk
View SE prooject. Then you’lll start FactoryTaalk Transaction Manager
M data coollection, which wwill collect produuction data and eevents
from the SoftLogix controller and will pass thhis data to FactooryTalk Metrics, which will recorrd the information in the FTMetrics
database.

Open and Run the Facto

oryTalk View SE
S Project

1. From the
t Desktop doouble-click on MetricsVA.cli,
M which is a shoortcut to the FaactoryTalk View
w SE client. Orr you
can seelect Programss > Rockwell Software
S > FactoryTalk View w > FactoryTaalk View Site E Edition Client.. If
you chhoose this optioon you must chhoose MetricsVVA.cli from thee next screen. If you get a FactoryTalk Secuurity
login dialog,
d enter Addmin/Admin ass the usernamee/password.

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2. You will
w see an HMI screen that is used for all of the
t workcells. Click on the L11Filler buttonn at the bottom of the
screenn to show data for that workceell. The screenn for L11Filler iis displayed, shhowing an overview of the staatus
for thee first machine in Line 1. We will
w come back to this screen and explain it in a moment.

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Start Data Collection
Now that thee factory (that is, the FactoryTalk View SE projeect) is initialized, you can begin ccollecting data foor FactoryTalk M
Metrics.
Tag data in the SoftLogix coontroller and FacctoryTalk View SES project is coll ected by FactoryyTalk Transactioon Manager, which
passes that data to FactoryT Talk Metrics. Too begin the data collection processs, you will needd to start the FacctoryTalk Transaaction
Manager coonfiguration usingg the Configurattion Console, whhich is the configguration program m for FactoryTalkk Metrics.

1. From the
t Windows Start
S menu seleect All Program
ms > Rockwel l Software > R
RSBizWare > C
Configuration
Consoole.

2. If prom
mpted, login using the default FactoryTalk Metrics
M administtrator account::
 Usser: Admin
 Paassword: Admin
n
 Seerver: localhostt (a keyword for the current machine); you couldd also use the IP
P address or nam
me of the computter.
 Click Login.

4. Click the
t Maximize button
b ( ) to maximize the Configuration
C C
Console if it is not maximizedd already.

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5. Start the FactoryTalkk Transaction Manager
M configguration, whichh collects data ffrom the simulaated factory in
FactorryTalk View SEE. Select Toolss > FactoryTalk Transactionn Manager > M Manage FactorryTalk Transacction
Manag ger Configuraations from the menu. Alternaatively, you cann click on the MManage FactorryTalk Transaction
Manag ger Configuraations link on thhe main Configguration Consoole screen.

6. Highligght the FTMetrrics configuration (stoplight) and

a click the Sttart button. It m
may take a minnute or so to staart the
FactorryTalk Transacction Manager configuration.
c After
A FactoryTaalk Transactionn Manager starrts the stoplightt will
turn grreen.

7. Click Close
C to close the FactoryTalk Transaction Manager Conffigurations dialoog box. Data iss now being
collectted by FactoryTTalk Transactioon Manager froom the running FactoryTalk V
View SE projectt and SoftLogixx
prograam and is beingg logged in the FTMetrics dattabase. There is also data in the database that goes backk into
the paast a few days ending
e with yessterday. Theree will be a gap between someetime yesterdayy and the curreent
time where
w there is no
n data in the database.
d

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Production Simulation in
i FactoryTalkk View SE

1. Returnn to the FactoryyTalk View SE client window.. Make sure yoou are seeing thhe L11Filler sccreen.

2. You arre looking at a display that shhows the statuss of one of the 12 work cells in our simulatedd factory. Unlike
some previous simulations that havve been used inn labs where thhe work cells aautomatically cyycled through
various simulated moodes for downttime, changeovver, etc., this siimulation is com mpletely manually controlled.. If
you doon’t change anyything on this screen,
s it will juust continue to simulate produucing product in a normal maanner.
So in order
o to obtain some “interestting” current daata for the lab, you will want tto invoke somee of the events that
are deefined here. Firrst we will look at the various parts of the sccreen.

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3. At the bottom of the screen
s are a seet of buttons too navigate to thhe screens for tthe other work cells in the
simulaation. There arre two lines deffined, and eachh line contains 6 work cells. LLine 1 contains the machines
whosee names begin with “L1”, and Line 2 contains machines whhose names beegin with “L2”. FactoryTalk M Metrics
m each of these 12 work cellss, as well as coomposite inform
is colleecting data from mation at the Line level. The w work
cell naames suggest a filling line, but that is just ann example. Thee screens are iidentical for eaach work cell,
although each screen applies to a different
d machine.

4. At the top of the screeen you will seee most of the data
d values colllected by FactooryTalk Metricss. They includee:
 Cyccle Time (sec) – this is the ideal cycle time for thhis machine to m
make one unit of production. Thiss can be changeed if
dessired, but it typiccally does not change unless thee Part Id being prroduced also changes. Ideal Cyycle Time is a keey
com
mponent of the OEE O calculation..
 Parrt counts – Totall, Good, and Scrrap. These are automatically
a inccremented by the simulation. Good parts are
prooduced at the ratte shown in the “Percentage
“ Goood Parts” field, w
which can be chaanged. To the rright is a button tthat
will reset the part counts.
c Note: this resets part couunts on the HMI screen only. FaactoryTalk Metriics will continue to
collect part counts normally if the counters
c are reseet.
 Thee list of fields on the right of the screen can be thhought of as “Coontext Fields.” TThese fields are collected by
FacctoryTalk Metricss and used for reeporting and filteering the resultinng data. We will use Part Id andd Operator later iin the
lab. On the screenn, these are free--form input fieldss and can be chaanged by clickinng on the field. A An input keyboarrd will
apppear. Type the new n value and clickc on Downloaad to update the field.

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5. In the middle of the screen
s you will see the machiine events thatt are collected by FactoryTalkk Metrics in thiss
applicaation. Clicking on any of thesse buttons will cause productiion to “stop” att the work cell, and a
corressponding event will be enteredd in FactoryTallk Metrics. Thee work cell will stay stopped ((and the “Runnning”
buttonn will be replaceed with “Not Ruunning”) until all the events arre cleared. Evvents must be triggered manuually;
this is not done in thee simulation.

The areeas labeled “RU

UNNING” and “Normal State” aree not buttons, buut indicators of thhe current condittion of the machine.
The Evvent Control and Line Control areeas contain buttons that can be pressed to activvate the indicateed event or condition.
The evvents are configuured in FactoryTalk Metrics as foollows:

Even
nt Eveent Name Event Vaalue Fault Severity Machine Button on V
View
Categ
gory State Screen

Fault Coooling Tunnel Yes Fault 0 Faulted Cooling Tunnnel

Tannk Low Yes Fault 0 Faulted Tank Low

Oil Failure
F Yes Fault 0 Faulted Oil Failure

Connveyor Failure Yes Fault 0 Faulted Conveyor

Drivve Stop Yes Fault 0 Faulted Drive Stop

State CIP
P Yes No 22 CIP CIP

Chaange Overs Yes No 25 Change Change Oveer

Overs

Blocck Yes No 20 Blocked Blocked

Starrve Yes No 21 Starved Starved

UnA
Available Yes No 70 UnAvailable Available

UnS
Scheduled Yes No 71 UnScheduled Scheduled

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 Runnning Yes No 100 Running RUNNING

EStopp Macchine EStop Yes Fault 1 E-Stops Machine Estop

Opeerator EStop Yes No 1 E-Stops Operator Esttop

This coonfiguration tablee may not be very meaningful att this stage, but iit will become clearer after we eexamine some reeports.

6. Go to the Event Con ntrol area of the screen and click

c on one oof the green Evvent Control bbuttons. In this
case Oil
O Failure wass pressed. Thiss will turn the button red, stopp production at the machine aand the Running and
Normaal State indicatoors will turn redd and show diffferent messagees. You can leeave the event on as long as you
like, annd turn the eveent off by clickinng the Event Control
C button aagain. Doing sso will create soome more interresting
data too look at later in the lab. We will
w come back to this screen several times in the lab to triggger an event.

If you choose
c either onne of the Estop buttons,
b you will be presented wiith a list of Estopp reason codes. You must chooose a
reasonn code from the list before you caan end the Estopp event.

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Lab Objectives

The objective for this lab is very simple: we want to find out how our simulated “plant” is performing, and we want to understand
how we might make it perform better. It is a simple question, but it has many dimensions and a plant is a complex system, so we
need some powerful tools to be able to answer these questions accurately. We will do this using the FactoryTalk Metrics
application that has been configured to collect data from the FactoryTalk View SE project, and the standard reporting interface
called Report Expert. We will also view some of this data using FactoryTalk VantagePoint EMI.
Here are the questions to be answered in the lab:
1. How well has the plant been performing?
a. What are some of the ways we can measure performance?
b. What is the worst performing line?
c. What is the worst performing machine?
d. What is the worst performing shift?
e. What is the worst performing part produced?
f. Who is the worst performing operator?
2. How can the plant’s performance be improved?
a. How can we start reducing downtime (or lost time)?
b. Can machine speed be increased?
c. Can Quality be improved?
3. What is happening right now?
4. How do we get the right information to the right people?

In answering these questions in the lab, we hope you come away with the following realizations:
1. These are the sorts of questions that every company needs to be able to answer about their operations.
2. These sorts of questions can be answered quickly and accurately using FactoryTalk Metrics

As mentioned earlier, we will be using mostly ad-hoc reporting capabilities as we answer the questions. Our application is not as
a finished application would be – we will be examining the “raw materials” of reporting that could be configured into a finished
reporting front end. We trust you can use your imagination to see how user requirement can be translated into saved reports.

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Introduction to OEE
FactoryTalk Metrics uses an Overall Equipment Effectiveness (OEE) model to measure the performance of manufacturing
equipment. The OEE model yields a single performance rating for every activity area (workcell, line, area, or plant), thereby
providing a simple way to determine quickly if an activity area is performing adequately.
The OEE value can be used to assess a single machine’s performance over time or to compare the performance of machines to
each other.
Three components contribute to an OEE value: availability, throughput, and quality. Each is a percentage, and the OEE value is
the product of these three percentages.
OEE = Availability * Throughput * Quality
OEE = (Good Parts * Ideal Cycle Time) / Available Time
Availability is a ratio of running time to available time. Available time may be defined by a schedule or modified by planned
downtime events such as preventive maintenance.
Availability = Running Time / Available Time
Throughput is the performance of a machine when it is running compared to its ideal cycle time.
Throughput = (Total Parts * Ideal Cycle Time) / Running Time
Quality is the percentage of good parts that are produced.
Quality = Good Parts / Total Parts
OEE is a valuable method of analyzing performance because it is widely recognized and can be applied to any type of industry,
factory, or machine. It is really a ratio of a machine’s actual performance to its ideal performance.
OEE is the default efficiency calculation performed by FactoryTalk Metrics, but it also provides other valuable performance and
production metrics. Furthermore, FactoryTalk Metrics supports the collection of detailed event data, which can be used to
analyze the specific causes of inefficiencies.
You should also think of OEE as a method of implementing cost reductions, since increasing the three components of OEE will
also reduce manufacturing costs.

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How well has the plan
nt been perfo
orming?

Our first queestion is a simplee one that can leead to any numbber of detailed quuestions – and tthat is just the pooint. One needss to
have a rich data store availaable to be able too answer the maany forms this quuestion can takee.

1. Launcch Internet Exp

plorer. The Hoome Page is seet to the Reporrt Expert home page, which iss
http://W
W2K8xPOC2:88001/rockwellsooftware/ReporttExpert/. “W2K K8xPOC2” is thhe host name.
Note: for Report Expeert to function prooperly, Internet Explorer
E mporary Internet files are refreshed on
must bee set so that tem
v to the page. This is alreadyy done in the imaage, but if you neeeded to changee this setting in Internet Explorerr, go to
every visit
Tools > Internet Optio ons. Select Setttings from the Temporary
T Internnet files section, and select Cheeck for newer verrsions
of storeed pages: Everyy visit to the page. Click OK unntil all menus aree closed.

On the left side is the Explorer

E area whhich contains a tree with folders and stored Report Expert reporrts. If the Explorer is
not visiible, click on thee Explorer buttonn in the Report Expert
E toolbar att the top of the ppage. The tree sshown here incluudes
the “ouut-of-the-box” repporting capabilities of Report Exppert. There are 69 reports instaalled in the Exploorer tree by default in 4
folders: Dashboards, Current
C Shift Reports, Yesterdayy Reports, This W Week Reports, aand Configuratioon Reports. Thee other
folders in the tree havee been added forr use during thiss and other labs. We will use thee reports containned in the My
Compaany folder in thiss lab. The Reporrt Expert Exploreer tree should bee customized forr each customerr application.
Changing the Explorerr tree is covered later in the lab.
Acrosss the top of the screen is a Report Expert toolbarr, including links to an Administrration screen, whhich is covered in an
advancced lab. The Explorer area can be hidden/displaayed by clicking on the Explorerr button in the tooolbar.
The rigght side of the sccreen is used to display reports.

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2. Maxim
mize the Interneet Explorer winddow. Open thee My Companyy folder, then thhe History foldder and click onn the
report titled Production Overview.. The report will render in thee right-hand paanel of the screeen. This reporrt
contains much of thee data we will need
n to answerr our list of que stions about hoow the plant is performing.

First, leet’s look at somee of the componeents of this repoort, which is typiccal of many repoorts in Report Exxpert. A report in
Reportt Expert consistss of two things:
 A Report
R Templatee which defines the data fields, chart
c contents, a nd formatting off the report. In thhis case the Repport
Tem
mplate is one of the default tempplates called “PrroductionOvervieew”.
 A Parameter
P Set, which
w defines thee filters for includding data in the report, and how
w the report conteents are groupedd and
sorrted.
The coombination of a Report
R Templatee and a Parameter set can be saaved to the Exploorer tree and givven a name, in thhis
case “P
Production Overrview”.

3. Examiine the header portion of the report. This seection containss:

Reportt Title: the title is taken from thee name of the enntry in the Explo rer tree you clickked on to renderr the report. If thhe
report is generated by some other metthod, such as byy manually changging parameter ssettings or drillinng through a report, the
report title
t will be the name of the repoort template.
Generaation time: this is a timestamp of
o when the repoort was generateed.
Parammeter Set: this iss the name of thee saved parameter set that is ussed to generate tthe report: Lab 1 History
Line/W
WC/Date/Shift/Hoour. The rest of the
t entries in thee header displayy the settings forr the parameterss that make up thhis
parameeter set. This paarameter set wass created for thiss lab.
me of the parameeter set implies, the
Grouping: This lists thhe fields by whicch the data in thee report is groupped. As the nam
data is grouped by Linee, Work Cell, Daate, Shift, and Hoour. All of thesee groupings are rrow-level groupinngs. You will seee the
results of these settings when we exam mine the body off the report.

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 Plant Model
M Filter: Thhere is no filteringg by Plant Modeel configured, so all elements of the Plant Model for which FactooryTalk
Metricss is collecting daata are included. So data from thhe 2 lines, each with 6 work cells, will be includeed in the report
Time: This
T shows the time t filtering thatt is in effect for the
t report. As yoou can see, dataa is included for the Past 2 weekks.
Our daatabase includess data in the mosst recent 6 days of that period. Your report will also include som me data that hass been
collecteed during the labb.
Sort: This
T shows if any additional fieldds (besides the Grouping
G fields) are used for sorrting the data in the report.
Plant Model Filteer and Time filter).
Filter: This shows if any filters are appplied to the data in the report (in addition to the P
TopN: This shows if there is a Top N fiilter operating aggainst the data. This is often ussed in Event repoorts, when you m
may
want too see data for onnly the Top 10 Evvents, for exampple.

4. Examiine the chart poortion of the report. It shows a bar chart of 4 data values ffor each Work Cell, grouped
togethher by Line. Thhis correspondss to the first twoo grouping fieldds defined in thhe parameter sset.

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5. Examiine the text porrtion of the repoort. This reportt was created w
with the ProducctionOverview report templatee and
the “Laab 1 History Linne/WC/Date/Shift/Hour” parameter set. All of the columnss beginning witth Uptime % annd
endingg with TEEP arre specified in the
t ProductionO Overview repoort template. Thhe five columns on the left – Line,
Work Cell,
C Date, Shifft and Hour – are a included onn the report beccause those fieelds are Row G Groupings in thee
parammeter set used tot generate thee report. In thee first two colum
mns of the repoort you can seee how each of tthe
work cells
c is associated with Line 1 or Line 2.

Production
nOverview Field
ds List:
The report contains
c a rangee of production innformation and performance
p me trics that is colleected by FactoryyTalk Metrics. It is
important too understand thee data that is shoown. The definitioons below refer to a “work cell” ffor consistency, but obviously thhe data
values referr to the row groupings used in the report.
Uptime % - This is the Availability portion of the OEE calculation and a meaasure of the perccentage of time the work cell is
running wheen it is expected to be running. The
T calculation is: Running Timme / Available Timme.
Performancce % - This is the Throughput poortion of the OEE E calculation andd a measure of how close to ideeal cycle the worrk cell
is operating when it is running. The calculattion is: (Ideal Cyycle Time x Totaal Parts) / Runninng Time.
Quality % - This is the Quality portion of thee OEE calculatioon and a measurre of the percenttage of product produced by thee work
cell is “goodd”. The calculation is: Good Parrts / Total Parts.
OEE % - Thhis is a measure of the overall peerformance of thhe workcell, and is the product off the Available %
%, Performance %,
and Quality %. This calculaation reduces to: (Good Parts x Ideal Cycle Timee) / Available Timme.
Available Time
T - This is thee total time that the
t work cell was expected to bee running.
Downtime - This is the amoount of Availablee Time where thee work cell was nnot running. Thee calculation is: Available Time –
Running Tim
me.
Running Time - This is the total time that thhe work cell wass running.
Good Partss - This is the count of Good production from thee work cell.
Scrap Partss - This is the coount of Scrap or bad production from
f the work ceell. In the OEE m
model, these scrrap parts have noo
value and thhe production tim
me to produce thhem is considereed wasted.
Total Parts - This is the couunt of Total prodduction from the work cell. Calcuulation is: Goodd Parts + Scrap P
Parts.
Ideal Parts - This value is calculated
c by FacctoryTalk Metriccs, and represen ts the productionn count that couuld have been atttained
under ideal conditions – no downtime, no sccrap, and producction at the ideall cycle time. Caalculation is: Avaailable Time / Ideeal
Cycle Time..
Scheduled Unavailable Tim
me - the total am
mount of time thee work cell(s) weere scheduled too be unavailable, represented ass

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HH:MM:SS. If more than one work cell is included, all unavailable Time is added together.
Faults – Total number of faults (for events configured as faults).
TEEP – TEEP is a KPI that some organizations use in addition to (or as an alternative to) OEE. Calculation is (Good Parts *
Ideal Cycle Time)/Total Time. Because it uses Total Time instead of Available Time (which is used in the OEE calculation) it is a
better measure of total machine utilization.

6. Go back to the FactoryTalk View SE application and trigger another event on the L11Filler screen.

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What are some of the ways we can measure performance?
Now that we understand some of the data that is being collected by FactoryTalk Metrics and shown in Report Expert, we can
start to answer some of the questions that were posed at the beginning of the lab. The first is to answer what we mean by
“performance”. As we can see from just one report, there are several measures of performance available to us, which might be
used for different reasons.
There are several data values in this one report can be used to evaluate performance, and others that are not shown in this
particular report. The ones that are visible here are:
 OEE% - a standard measure of overall equipment effectiveness, which takes into account availability, throughput, and
quality.
 Uptime % - a measure of running time vs. available time, and a component of OEE.
 Performance % - a measure of actual production speed vs. ideal production speed while running, and a component of OEE.
 Quality % - a measure of good parts produced vs. scrap parts, and a component of OEE.
 Available Time – a measure of total time a machine is expected to be running.
 Downtime – a measure of time when a machine is expected to be running, but is not running for any reason.
 Running Time – a measure of time when a machine is running.
 Scrap Parts – a measure of production output that, for whatever reason, cannot be used. Scrap can represent both wasted
machine capacity as well as wasted material cost.
For the lab questions, we will focus on OEE as a performance measurement.
Further, performance can be measured in many different contexts. We will vary the context to answer the series of performance
questions we want to answer.
 Plant Model – performance can be measured at any level of the plant model, which has a hierarchy of
Enterprise/Site/Area/Line/Work Cell.
 Month/Week/Date/Hour – performance can be measured by any number of time periods.
 Shift – performance can be measured by shift. Different parts of the plant model can have different shift patterns.
 Part Id – performance can be measured by the product being produced.
 Operator – in our example application, we are collecting Operator as a data field that provides context to other data.
FactoryTalk Metrics supports the collection of up to 5 such fields, which are called Flex Fields and can be customized for
each application.
Finally, performance can be measured in different timeframes:
 Historical – looking at historical data is useful for analyzing trends and patterns. A longer view is valuable for determining the
priority of performance issues to be addressed. The Production Overview report is an example.
 Current – looking at current data is crucial for determining courses of action that can improve performance in real time.
Operator dashboards are typically used to display current information, or at most information from the current shift.

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What is th
he worst performing line?
Now let’s annswer our speciffic questions on the performancee of our plant. Itt makes sense too start at a fairly high level, by
comparing the
t performancee of our two liness to each other.

1. Click on
o the box nextt to Click to hide/show charrt to hide the chhart so it is eassier to see the tabular data onn the
report.

2. Note the work cells (machines) thatt are containedd in each of thee lines. Click oon the box next to Line 1 to hiide
the daata for the workk cells in Line 1 and just show
w data for Line 11. Do the sam
me for Line 2.

3. Now thhe report just shows

s data at the line level, which
w representts the sum (or average) of thee values at thee work
e to see thaat Line 1 out-peerforms Line 2 iin OEE %. The difference in OEE % appeaars to
cell levvel. Now it is easy
be duee in part to a higher Uptime %,
% so it makes sense
s that Linee 1 also has lesss Downtime aand more Runnning
Time than
t Line 2. We
W can also tell from this report that at the Liine level, the plant is running between 79 annd
84% OEEO on average over the timee period.

Answer: The worst-p

performing Line
L (using OEE
O %) is Lin
ne 2. That wa
as pretty eas
sy!

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What is th
he worst performing machin
ne?
Let’s dig a liittle deeper and see if the poor performance
p of Line
L 2 is due to tthe poor perform
mance of a singlee machine, or
something more
m widespreadd. It might be that improving thaat one machine w will improve the performance of the entire line.

1. Click on
o the “+” signn next to Line 1 and Line 2 in the report to shhow the work ccells in each linne. The colors oof the
OEE % column, are configured to be b red for valuees up to 50%, yyellow up to 755%, and green above 75%, soo we
can’t tell just by lookiing at the colorrs what the worrst-performing work cell is.

2. We coould look at the data closely too see which woork cell has thee lowest OEE % in Line 2, butt let’s get somee help
from Report
R Expert innstead. In the Report Expert toolbar, click oon the Parameeters button to expose the
Param
meters panel.

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3. This panel shows thee parameters thhat were used to generate thee current reporrt. The settingss here will match
those in the heading of the report. By changing thhe Parameterss here, we can change the repport dynamically –
which is very useful for
f doing ad-hooc reporting to answer specifiic questions likke the ones we have posed. C Click
on thee Sorting parammeter to open it.
i

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4. Selectt OEE % from the t drop-down list of fields. You
Y can type thhe letter “O” to choose just thee entries that sstart
with thhat letter. Leavve the default setting
s of Asc, which will sort the OEE % in ascending order, with the low west
value first.
f

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5. Click on View Reporrt. The report will be re-run with
w the new paarameter setting.

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6. Now thhe same reportt is rendered soorted by OEE %.
% Within Linee 2 (which is firrst because it hhas the lowest O
OEE
%) L255CasePack haas the lowest OEE
O % and apppears first. Notte that the charrt shows the saame order. Thee rest
of the workcells in Line 2 have a sim
milar OEE %, but
b for simplicitty let’s look jusst at L25CaseP
Pack. Click on tthe
“+” siggn next to L25CCasePack to see
s data by datte.

7. Now wew see that oveer the 5-day peeriod, the perforrmance of L25C CasePack hass varied substantially; from a llow of
64% ono one day andd a high of almoost 95% on anoother (the dates you see will bbe different froom the ones shown
here – the most receent date will be today). As preescribed in ourr Parameters, the dates are sorted by OEE %.
So thiss machine is caapable of runniing at an OEE that approachees 95%, which is extremely hhigh, but more ooften
than not
n has problem ms reaching thaat level. Note that
t on the worrst-performing ddate the Uptim me % is lowest aand
the Doowntime is highhest – indicating an excessivee downtime prooblem on that ddate. Click on the “+” sign neext to
the daate with the low
west OEE valuee to see data byy shift.

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8. This process of expaanding and collapsing by grouuping fields is ccalled Drill-Dowwn and it is a fuundamental feaature
in mosst Report Expert reports. Ourr simulation runns two 12-hourr shifts per day. Drilling downn to the shift levvel the
historyy of L25CasePaack on the dayy in question beecomes clearerr still. Shift 1 raan quite well, w
while Shift 2
experienced over 7 hours
h of Downttime, contributing to an OEE oof 39%. Click on the “+” signn next to Shift 2 to
see daata by hour.

9. At the hourly level, it is pretty clear what happened with L25CassePack – it hadd a very bad shift on this particcular
day. Remember
R the hours are sortted by OEE %, so they are noot in numerical order. It appeears that
L25CaasePack stoppeed running durring hour 0 and stayed down tthrough hour 66. It appears thhat this extendeed
periodd of downtime was
w a significannt contributor too making L25C
CasePack the w worst-performinng machine forr the
entire period of the reeport.

You haave just seen thee built-in ability too drill-down and drill-up through the grouping fieelds that appear on any Report E
Expert
report. This is especiaally powerful in thhe ProductionOvverview report, w which supports 5 levels of row grroupings – the oother
report templates
t mostlyy support 3 levels.

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10. Go back to the FactoryTalk View SE application and trigger another event on the L11Filler screen.

Answer: The worst-performing machine for this period (using OEE %) is L25CasePack, although
the rest of the machines on Line 2 have very similar performance, and its performance has varied
considerably.

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What is th
he worst performing shift?
Performancce levels can alsoo vary by shift, due
d to any numbber of reasons - sschedule differences, staffing levvels, skill level oof
operators, etc.
e Assuming thhat shift informattion is configuredd, FactoryTalk M Metrics includes shift informationn with all collecteed
data, so repporting by shift iss standard practice. In our exam
mple all work cell s are on a 12-hoour shift schedulle, and the shift start
times differ for the two lines.

1. Changge Grouping parameters

p to group
g by Shift, Shift Start, annd Work Cell, as shown beloow. Delete the fourth
and fiffth groupings using the “X” buuttons. This will enable us to view all the daata for one shiftt together. Thee
differeence between grouping
g by Shift Start insteadd of Date is thaat Shift Start wiill display the ddate and time oof the
beginnning of the shiftt, and will keepp all informationn for that shift instance togethher, even if the shift crosses a date
bounddary. Click Vieww Report.

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2. Shift 2 is listed first because
b it has the
t lowest average OEE % foor the time periiod of the report at about 76% %.
Shift 1 is over 86% foor the period. Listed under Shift 2 is each innstance of a Shhift 2 that occuurred within thee last 4
days. There are twoo Shift Start times for each date, because Shhift 2 on Line 1 begins at 6:000PM, while Shifft 2 on
Line 2 begins at 7:000PM, and becaause the report is grouped by Shift Start thesse are listed seeparately. Thee shift
instances are ordereed based on thee average OEE E % for the shifft for all machinnes on that shifft schedule. Yoou can
see cleearly that theree was one really poor instancee of Shift 2 durring this period, which shows as a red OEE
score, and that Shift 2 has more yeellow OEE scorres than Shift 1 . Click on the “+” sign next tto the first entrry to
see the work cell datta for the worstt shift instance..

3. Lookinng at the detailss by work cell, it looks like theere was a probblem with all of the Line 2 worrk cells during tthat
shift period.

Remem mber when we determined that L25CasePacker

L had a really badd shift on 4/17/20012 between midnight and 7:00A AM?
(Your dates
d will be diffeerent.) This is the same shift. Thhe shift was 12 hhours long and sstarted at 7:00 P
PM on 4/16/20122.
Earlier we saw the datees and hours during which the data d was logged (4/17 between m midnight and 7:000), and here wee see
all the data for that shifft instance assocciated with the shift
s start time (4//16 at 7:00PM).

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Answer: The worst-performing shift (using OEE %) is Shift 2.

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What is th
he worst performing Part?
One of the data
d values that FactoryTalk Meetrics is collectingg from each worrk cell is the Partt Id of the producct that is currenttly
being produuced, which appeears on the FacttoryTalk View SEE HMI screen. TThis allows reporting of all data bby Part Id, whichh is a
standard caapability of FactooryTalk Metrics.
This will alloow us to look at performance
p datta (as well as all other data) on a part by part baasis, to see if thee production of ssome
Part Ids is especially
e problematic.

1. Changge the Groupingg parameter too Part Id, Line, and Work Ce ll.

2. So far, we have displayed all data sorted

s by OEE %, so we havee to examine thhe report to deetermine which is the
worst-performing Line, Work Cell, Shift,
S etc. Let’ss have Report EExpert do some of this work ffor us, especiaally
since there
t could be a very large nuumber of Part Id I values in thee database. Open the TOP N parameter window.
Choosse Bottom from m the drop-dow wn list and enteer 5. Then chooose Part Id froom the of field list and OEE % from
the ussing list. This will
w return just the
t Bottom 5 Part
P Ids using O OEE % as a meeasure. Note that there are 770
differeent fields in the using list that can be used asa a measure foor this filter. Click View Repoort.

3. The reesulting report shows

s only thee worst-perform
ming Part Ids. O
Our data set is very limited, annd there are onnly
Part Idds in it, so both are shown, buut obviously a real
r data set coould have thousands of differeent Part Ids loggged,
in whicch case only thhe worst 5 would be shown. ThisT shows us something inteeresting – it loooks like the ‘12 oz’
performms worse than ’16 oz’ overalll, but the worstt combination oof Part and Linee is ‘16 oz’ on Line 2. Based on
this veery simple analysis, one couldd make a case that it is most efficient to prodduce ‘12 oz’ onn Line 2 and ‘16 oz’
on Line 1.

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4. Let’s use
u another one of the filteringg parameters to
t further focuss this report on a specific partt of the plant. LLet’s
say that the most impportant asset on
o each line is the
t Filler, whicch is typical on a filling line. O
Open the Plant
Modell parameter winndow and select just the Filler work cells onn both lines – LL11Filler in Linee 1 and L21Filller in
Line 2. Click View Report.
R

5. Now thhe report is limited to the 5 woorst-perfuming Part Ids produuced on the Fillers in both linees. In this casee, the
resultss closely mirrorr the results forr all the work ceells. If you clicck in the “+” sign next to one oof the lines, youu can
see that only one woork cell is used in the calculatiions.

6. EXERRCISE – Can yoou create a parrameter set for this report whiich would tell yyou which Part Id each Line
producces most efficieently?

7. Go back to the FactooryTalk View SE application and

a trigger anoother event on tthe L11Filler sccreen.

Answer: The worst-p

performing Part
P (using OEE %) is ’12 oz’.

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Who is thee worst perforrming operato
or?
One of the data
d values that FactoryTalk Meetrics is collectingg from each worrk cell is the Opeerator, which apppears on the
FactoryTalkk View SE HMI screen. Earlier we w called Operattor, Part Id, and several other fieelds on the screeen “context fieldss”.
The kind of filtering and reporting that you juust saw for Part Id can also be ddone with Operator, or with any oof the other conttext
fields.
In order to do Talk Metrics has a feature called Flex Fields, whiich allows for thee configuration oof up to 5 fields tto be
d this, FactoryT
collected froom the control syystem that can provide
p context too all other data ccollected. Part IId is a standard field with this
behavior, buut Flex Fields allows each custom mer to choose a different set of data fields for thheir application. Operator is a coommon
one, but othher data such as Batch, Work Orrder, Customer, Sales Order, etcc. can also be caaptured using Flex Fields, providded
that this infoormation can be taken from dataa points in the coontrol system.

1. Changge the Groupin

ng parameters to Operator, Line
L and Shift..

2. Edit thhe Plant Model parameter to select all workk cells. This caan be done by uun-checking thhe two Fillers that
are seelected. If nothing in the Plant Model is selected, then dataa for all work ceells is returnedd.

3. Removve the Top N parameter

p by clicking
c on all thhree of the “X” so we can seee all of the Opeerators on the reeport.
Click on
o View Reporrt.

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4. Now we
w see the Opeerators, which Lines L they workk on, and whicch Shifts they wwork. If all this is not visible, exxpand
the Drrill-down “+” siggns until you caan see it all (you can also speecify whether a grouping appeears initially as
collapssed or expandeed in the Groupping parameterr). There are ssome interestinng observationss that can be m made
here, remembering
r that we alreadyy know that Linee 2 is our worsst line, and Shifft 2 is our worsst shift:
 Ricck is the worst-peerforming operattor by almost 100 percentage poi nts. Rob is the bbest, and is almoost 20 points bettter
thaan Rick. Perhapss Rob can help Rick
R to improve..
 Skippy has the majjority of operating time on Line 2, 2 which is the w
worst line. Perhaaps the operatorss could be crosss-
traiined or reassigned, to determinee if the overall prroblems with Lin e 2 are related tto human factorss.
 All Operators have worked on bothh Shift 2 and Shifft 1, and in eachh case, their efficciency on Shift 2 is less than Shiift 1.
Joee’s performance is especially diffferent on the twoo shifts. So theree may be sometthing about Shiftt 2 which is
independent of Opeerators that is im
mpacting efficiency.

Answer: The worst-p

performing operator (usin
ng OEE %) is
s Rick.

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Drill-Throu
ugh and Expo
orting Report Data
D
We will takee a break from annswering questioons to briefly demonstrate two im
mportant featurees of Report Exppert: Drill-through and
Exporting daata.

1. Lookinng at the Produuction Overview

w Report, what is shown is alll the data for all the Operatorrs for the periodd.
Now we o more poweerful feature of most of the Reeport Expert staandard report ttemplates: drill-
w will look at one
througgh. Move your mouse to the Available
A Timee value for the Line 1 value uunder the Operrator Rick. You will
Click on the Available Time vvalue.
notice that your cursoor changes to a hand, indicatting that the vaalue is a link. C

2. A neww report is geneerated, and youu have now drilled-through to another level oof detail. The reeport template is the
same, but the report contains only the
t data from the
t row in the pprevious reportt that was drilleed through. Exxamine
the heeader area of thhe report and you
y will see that new filters haave been applieed to the reporrt which limits thhe
data too the Operator Rick and Line 1. The grouping has also beeen changed too Work Cell.

41 of 102
3. There are two important points to remember regarding the drill-through capability:
 The data that is passed to the drill-though report depends upon the Row in the originating report that you click on. The
data passed to the drill-through report is filtered to contain only data from the row you clicked on. The resulting report
takes the data from that single row, but adds a new row grouping to the drill-through report to displays data with more
granularity. There is a set progression, or hierarchy of data grouping as you drill deeper The hierarchy of drill-through is
as follows:
a. Site
b. Area
c. Line
d. Work Cell
e. Month
f. Week
g. Day
h. Shift
i. Hour
As we saw in the above example, if you drill-through on a row of a report that contains data that is grouped by Line
(level c), the resulting report will be grouped by Work Cell (level d). Similarly, if we had drilled-through on a row that
was grouped by Shift (level h), the resulting report would be grouped by Hour (level i).
 Most data field (non grouping fields) in most of the standard report templates has drill-through behavior. In the
Production Overview report, this means that every data value in the Uptime % column and every column to the right of
Uptime % is a link to another report. The Column that you drill-through determines the report template that is used for
the drill-through report. The chart in Appendix A shows the drill-through report destination for each column in every
standard report template that supports drill-through.

4. Click on one of the values in the Total Parts column to drill-through to the next level of detail.

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5. Becauuse we drilled-through on a different column than before, w we go to anotheer report template called
Production Report, which
w shows soomewhat differeent data. We ddrilled-through from a report ggrouped by Woork
Cell, and
a the next levvel of the hierarchy is Month. Our time filterring includes juust the Last 2 W
Weeks, so grouuping
by Month is skipped and we go to the next lowestt level, which iss grouping by W Week. There iss data from jusst one
week, so only one roow is shown.

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6. Drill-thhrough any of the data valuess, and you will see
s another Prroduction Repoort, now groupeed by Date, which is
the neext lowest level of the drill-throough hierarchy. It seems that Rick only workked on the L11Fillerfor two daays in
this weeek. If you conntinue to drill-thhrough, you will get to the lastt two levels: Shhift and then Hour. Use the B
Back
buttonn in the browser to return to thhe Production Overview
O reporrt.

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7. Experiiment with drilliing-through on other data fields in the Produuction Overview
w report. You can access a ttotal
of 7 otther Report Temmplates by drilling-through the various colum mns. Clearly, tthis drill-througgh functionality offers
a greaat deal of reportting flexibility with
w no effort byy the user.

8. Next wew will export thhis report data to Excel. In thhe toolbar at thee top of the paage, click on thee Export icon aand
select Excel from thee drop-down lisst. You will gett a File Downlooad dialog asking if you want to Open or Save
this filee. Click Open..

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9. Excel will open and the t report will appear,
a just as it is rendered iin Report Expeert. You may gget a message that
the filee is from a site that is not trussted – you can ignore this warrning. You cann even drill-thrrough the dataa
valuess in the spreadssheet, and youu will be taken to t the proper R Report Expert ddrill-through repport! Close Exxcel
when you y are finisheed.

10. Go back to the FactooryTalk View SE application and

a trigger anoother event on tthe L11Filler sccreen.

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What have we learned so far?
We have been looking at data from our simulated plant for a very short period of time, but we have already learned a great deal
about how it has been performing in the last few days.
Using OEE %, which is just one of the many metrics, or measurements, in FactoryTalk Metrics, we have determined that the
plant’s lines are running between 75% and 85% OEE, and have identified the worst-performing:
 Line (Line 2)
 Machine or Work Cell (L25CasePack)
 Shift (Shift 2)
 Part (12 oz)
 Operator (Rick)
We have identified some big performance problems that were confined to just a few shifts during the week.
The process of answering these questions has led to an ad-hoc approach to reporting in this lab, but hopefully it has also
communicated that the necessary data to analyze performance in great detail is present in FactoryTalk Metrics, as is the ability
to present it easily and effectively. We hope you are convinced that you can locate and visualize the data that you need to
answer the important questions necessary to improve plant performance and reduce costs.
We have also shown some specific features of Report Expert so far:
 The ability to dynamically change parameters for ad-hoc reporting
 The ability to change reports by altering Grouping
 The ability to Sort data in reports
 The ability to filter data using the Plant Model
 The ability to filter data based on Top N or Bottom N calculations
 The ability to Drill-down and Drill-up within a report
 The ability to Drill-through data values in reports to show more detailed information
 The ability to export report data to Excel
And so far we have only looked at one of the available Report Templates!
Let’s move onto the next set of questions, where we will begin to find some answers about how the performance at our plant
might be improved.

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How can the plant’s performance be improved?

Now that we have done some assessment of how the plant is performing, the next obvious objective is to make it perform better.
Unfortunately, FactoryTalk Metrics by itself cannot make a plant perform better, but it can help plant personnel make informed
decisions about where improvements should be made.
From an operations point of view, there are really only three ways to improve the performance of a machine (or on a larger scale,
a plant that contains many machines):
1. Increase the running time of the machine, so that it is producing when it is supposed to be. This comes from minimizing
downtime and other forms of lost time, or conversely increasing uptime.
2. Increasing the production speed of the machine, so that when it is running, it is producing at the maximum it is capable.
3. Producing less scrap. Producing product that cannot be used wastes both production capacity and material cost.
These three ways also correspond to the three components of OEE: Availability, Performance, and Quality.
Let’s look at each of these three ways and see if improvements can be made in our simulated plant.

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How can we start reducing downtime (or lost time)?
Decreasing downtime and maximizing uptime is fundamental to improving efficiency. But downtime is a complex multi-headed
beast, and having accurate data is critical to understanding the underlying causes of downtime and prioritizing the attack against
it.
When configuring a FactoryTalk Metrics application, there are two separate components that must be configured to track
downtime in a meaningful way:

1. Custom Events. We introduced the custom events that are configured for every workcell in our simulation
earlier in the lab document. The table that was shown earlier is duplicated here.

Event Event Name Event Fault Severity Machine State Button on View
Category Value Screen

Fault Cooling Tunnel Yes Fault 0 Faulted Cooling Tunnel

Tank Low Yes Fault 0 Faulted Tank Low

Oil Failure Yes Fault 0 Faulted Oil Failure

Conveyor Failure Yes Fault 0 Faulted Conveyor

Drive Stop Yes Fault 0 Faulted Drive Stop

State CIP Yes No 22 CIP CIP

Change Overs Yes No 25 Change Overs Change Over

Block Yes No 20 Blocked Blocked

Starve Yes No 21 Starved Starved

UnAvailable Yes No 70 UnAvailable Available

UnScheduled Yes No 71 UnScheduled Scheduled

Running Yes No 100 Running RUNNING

EStop Machine EStop Yes Fault 1 E-Stops Machine Estop

Operator EStop Yes No 1 E-Stops Operator Estop

It is important to configure all events that can stop the machine, and to be able to distinguish one from the other. This is
often dictated by the PLC programming, and sometimes it is necessary to augment the existing PLC code to include
additional logic to detect situations that can cause downtime.
In our simulation, the events shown above include every reason that the machine can stop, as well as a running indicator.
Event Category - Each event is included in one of the three Event Categories, which is just a logical grouping of events for
reporting.
Event Name – used for reporting
Event Value – This appears in reports as Reason Code. In our project it is used two ways. The two E-Stop events also
collect an event value that explains the reason for the E-Stop. Usually this is presented as a list on an HMI screen so that
the Operator can choose a reason for an event, as it is in our simulation. The other way that Event Value is used is to

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 populate it with a text string
s similar to the
t Event Descriiption, which is w
what is done for events that do nnot have multiplee
reasonn codes.
Fault – indicates that the event represents a fault, whicch is used to callculate measurees like MTBF (Meean Time Betweeen
Failuree) and MTTR (Meean Time to Reppair), which is doone automaticall y by FactoryTalkk Metrics.
Severity – a number frrom 0-100 that inndicates the seriiousness of the eevent. A 0 is moost severe. Thee severity value ccan be
used too filter or group similar
s events in reports.
Machinne State – Evennts can drive Machine States, whhich are explaineed below. In thiss column is the M
Machine State thhat is
invokedd with each evennt.
Button
n of View Screeen – the label on the button of thee FactoryTalk V iew SE screen that triggers and ends this eventt.

There is a new Report Template in Report Expert 2.200 that displays in formation aboutt how Events aree configured in
FactoryyTalk Metrics. Inn the Report Expplorer tree, naviggate to Configu ration Reports and choose eithher of the reportss in
that folder. Displayed will be Event infoormation shown in the table aboove, as well as m
more detailed infformation on how
w the
event uses
u data pointss in the control syystem.

2. Machiine States. FaactoryTalk Metrrics has a built--in State Enginne that can be cconfigured to bbe driven from
Eventss that are collected from the control
c system.. Up to 100 Maachine States ccan be configured in a FactorryTalk
Metriccs application. The following are
a configured in our applicattion:
Mach
hine State Priority
UnSccheduled 1
UnAvvailable 2
CIP 3
Faulteed 4

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 E-Stops 5
Change Overs 6
Blocked 7
Starved 8
Breaks 9
Setups 10
Maintenance 11
Initializing 12
Running 13
Idle 14
Down 15
Undefined 100
If a workcell is configured to use Machine States (which all the workcells in our application are), then the workcell can be
in one and only one Machine State at all times. Since Machine States are driven by Events, and more than one Event
on a workcell can occur at the same time, the Machine State logic in FactoryTalk Metrics sorts out what Machine State the
workcell should be in at all times based upon the Machine State priority.
Machine States are commonly used to:
 Account for all time in user-defined categories, which is not possible to do by tracking individual events which can occur
simultaneously.
 Account for time in categories that are consistent between workcells, even though the workcells will have different
events.
You can look at the Machine States that are configured in the Configuration Console. Go to Configure > FactoryTalk Metrics >
Machine States.

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Now that yoou have a good idea of Events and Machine Stattes are tracked iin FactoryTalk M
Metrics, let’s starrt determining whhat the
top causes of
o downtime andd lost time are inn our plant. We will
w start by lookking at some Macchine State histoory data.

1. Click on
o the Exploreer button in the Report Expertt toolbar to hidee the Parameteer window and show the Repoort
Explorrer window.

2. In the Report Exploreer tree, click onn Machine Staate Summary inn the My Company/History folder. You will see
a summary of Machine State inform mation for the entire
e plant moddel for the last 5 days, sortedd so that the Maachine
State with
w the most time (State Durration) comes first.
f This givess us a high-levvel view of how the shift time ffor all
work cells
c is divided between the Machine
M States. Fortunately, tthe Machine Sttate with the most time is Runnning.
The neext two States with the most time
t are CIP (CClean In Place)) and Starved, each of which are worth diggging
into. CIP
C frequency iss an operationss issue, and Sttarved conditioons are often caaused by downntime on upstreeam
machines. So we will focus on the Faulted State, primarily becaause Faults muust be minimizeed, and in our pproject
Faults can be causedd by any of fivee different evennts (see the preeceding Custom m Events tablee). Click on thee “+”
sign next to Faulted..

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3. Now we
w can see the distribution of Faulted Machine State time aacross the worrk cells, as welll as the count oof the
numbeer of times each machine wennt into a Faulteed Machine Staate, minimum dduration, maxim mum duration, eetc.
The firrst Work Cell entry shown herre (L1S) is a sppecial one wheere the entire linne is configured for data colleection,
and we will ignore that special casee for now. Thee Work Cell withh the highest FFaulted time is L11Filler. Click on
the State Detail link for L11Filler too see details.

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4. Now we
w see details ono the 38 timess that L11Fillerr went into a Faaulted State. R
Remember from m the table of
custom
m events earlieer that any of 5 different eventts contained in the Fault Evennt Category coould have triggeered
these Faulted Machine States. Lett’s find out whicch Events are ccausing the moost Faulted time.

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5. Click on
o Event Summary in the Reeport Explorer tree. t This will render a savedd Event Summary report that
showss information onn all custom evvents for all thee work cells.

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6. Click on
o the L11Filler work cell to show the informmation for all cuustom events foor that machinee. Note the repport is
sortedd by Event Duraation, so the largest Total Durration values w
will appear first..

7. Let’s narrow
n the focuus of this reportt to show just events
e in the Faaults Event Caategory for the L11Filler work cell.
Click on
o the Parameeters button to expose the parameters windoow. Open the Plant Model filter and selectt just
the L11Filler, our woork cell with thee most Faulted time.

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8. We will introduce a new
n Parameterr. Open the Filttering parametter and choosee Event Category from the drop-
down list.

9. From the
t resulting vaalue drop-downn list, select Faault. This will seelect only the ffive events thatt belong to the Fault
categoory, which are the
t ones that also
a invoke the Faulted Machiine State. Theen click on View w Report.

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10. Now wew have the data for just the Faults
F events, which
w are the oones that invokke the Faulted Machine Statee.
Click on
o the “+” nextt to L11Filler too look at the deetail for that maachine. Now w we can begin to see some of the
detail on what is causing those Fauults. The numbber one culprit ffor this machinne is Oil Failuree. Remember, you
are loooking at data summarized oveer 5 days. Youu can drill-throuugh any of the numbers on thhis report to seee the
data inn progressivelyy more detail. To
T see the raw w detailed eventt records, clickk on Event Dettail on the line
corressponding to L111Filler Oil Failure.

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11. Listed here are details on the 37 Oil Failure eventts that occurredd at the L11Filller machine in the past 5 days.
Since this is the num mber one Fault cause on the machine
m with thhe most Faulteed time, it’s a prretty good thingg to
prioritize to fix. Isn’t this
t the kind of information thaat plant mainteenance crews w would love to have available??
FactorryTalk Metrics can’tc fix this problem for you, but it can helpp you identify w
which problemss are having thee
greateest impact on thhe efficiency off the plant.

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12. For annother way to loook at all of thee Events that are occurring onn the L11Filler machine, go too the Report
Explorrer and click onn Event Chart L11Filler. This report has beeen configuredd to show an Evvent Chart repoort
templaate, showing evvents from just the L11Filler work cell, wherre all events arre shown except Running – sso
these are all the events that can caause the machine to stop runnning. This is a very powerful report that givees a
more complete
c view of all the issuees that are impaacting the Uptimme of L11Fillerr. A few reportts back, we saw w that
CIP annd Starved werre the biggest problem
p in the plant as a whoole, but this woork cell’s numbeer one time losss is
due too Oil Failures.

This reeport shows Event Duration and Event Count groouped by Event Category in the top chart, and thhen each value
separaately in the bottom
m two charts. The bottom part of o the report is s imilar to the Eveent Summary repport we just saw w. As
with othher reports, you can drill-throughh on any data vaalue, and in this report you can aalso drill-throughh the data on thee
charts.

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13. So wee know that Oil Failure is a bigg culprit for dowwntime for L11FFiller, but is it tthe biggest dow
wntime cause
elsewhhere? Let’s usse this report too find out. In thhe Parameters window, go to the Plant Moddel parameter aand
de-sellect L11Filler to
t show all machines. In the Filtering
F param
meter, delete thhe Event Seveerity filter and seelect
Event Category andd choose EStop and Fault froom the list. Thiis will eliminatee the State Eveents from the reeport,
includiing CIP, Changge Overs, etc. Click View Reeport.

Note: Event Seveerity is a high-peerformance filter for Event data, but not as easy to understand aas Event
Caategory or Event Name.

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14. This confirms that Oiil Failure is the Fault with the largest amounnt of lost time foor the entire plaant. Other Fauults
happeen more frequently, so it usefuul to see a stacck-ranking bothh by Count and by Duration.

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15. Finallyy, let us see hoow we should prioritize
p efforts to reduce Oil FFailures by seeeing how muchh downtime eacch of
the woork cells has is due to this reaason. In the Parameters windoow, set the Groouping to Linee and Work Ceell. In
the Filltering parameeter, select Eveent Name and choose Oil Faailure. Click Viiew Report.

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16. This gives us a clearr picture that the Oil Failure exxists almost enntirely in two woork cells on Linne 1 – L11Fillerr and
L15CaasePacker. L1S is a speciallyy-configured woork cell that traacks data from two critical maachines on Linee 1 to
give a line-level view
w of performancce. Those criticcal machines hhappen to be thhe same ones that are
experiencing Oil Failures. So this gives
g us a clear plan of attackk – eliminate OOil Failure on thhese two machiines
and we will have elimminated the num mber 1 cause ofo Fault-relatedd downtime in tthe plant.

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17. There is another mettric that the maaintenance crew ws will find invaaluable – Meann Time Betweeen Failure (MTB BF).
Remember that some of the custom m events were defined as Fauults, which in thhis case is a sppecial kind of
FactorryTalk Metrics event
e used to calculate
c MTBF F and other fauult metrics. The events with tthis definition
includeed the 5 eventss in the Fault Event
E Categoryy and the Machhine E-Stop eveent. Click on thhe Fault Summ mary
report in the Report Explorer
E tree. This report, whhich is sorted bby MTBF, show ws L11Filler at tthe top of the list,
which means that it experiences
e faults more oftenn than any otheer machine in thhe plant.

The report contains valuable metrics foor determining thhe reliability of a machine:

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 MTBF – Mean Time Beetween Failure, a standard measurement of ma chine reliability. Calculation is R
Running Time / FFault
Count.
MTTR – Mean Time Too Repair - the avverage time in Faault, or the averaage time it took to restore a macchine to running state.
Calculaation is Fault Tim
me / Fault Countt.
Faults per Hour – the average numbeer of faults experrienced per runnning hour. Calcuulation is Fault C
Count / Running hhours
Fault % - Fault Time as a percentage of
o Running Timee. Calculation iss Fault Time / Ruunning Time.

18. Finallyy, let’s look at downtime

d for soome specific pooorly-performinng shifts, to seee if there is som
me other approoach
we shoould take to redducing downtim me. Remembeer when we werre evaluating thhe plant’s perfoormance earlieer in
the labb we saw that there
t was at leaast one very pooor-performingg shift. Let’s take a closer loook at one of thoose to
determmine what happpened. Click on Shift Historyy in the Reportt Explorer tree..

19. This version of the Production

P Overview report temmplate shows every shift occcurrence in our data set stackk-
rankedd by OEE %, soo the worst-performing shifts are shown at tthe top. Each line has a diffeerent shift start time,
so those appear as separate
s rows in the report. The
T worst-perfoorming shift is quite clear. Yoour dates will bbe
differeent from those shown
s here.

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20. Expannd the first shift on the report to
t show detailss by work cell. We looked at tthis shift earlieer. It seems thaat all
work cells
c on the linee had problemss during that shhift. Make a noote of the Shift Start date and time, we will bbe
using that
t in a few minutes.
m

21. Let’s innvestigate this particular shiftt further by usinng another rep ort template. IIn the Report E
Explorer, open the
Dashb boards folder anda click on thee Machine Staate History repport. This is onne of the entriess in the tree thaat is
installeed by default.

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22. You will
w see a report that shows thee machine state history for the last 30 minuttes. This is current data, not
historical data from the last 5 days. We will use thhis report, but cchange the parameters to show the data froom
our woorst-performingg shift. Click onn the Parameteers button to oopen the parammeters window.

23. We will use a parameeter that allowss us to filter data by date and time. In the D
Date/Time/Shiftt parameter, click on
the second button froom the left, which is Specify a Time Rangee with Start annd End Dates.

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24. Our worst shift was Shift
S 2 that starrted on 4/16/20012 at 7:00 PM M (yours will be different), so eenter that date and
time inn the Start fieldds. If you click on the calendaar icon next to each field you will get a calenndar control. EEnter
the same date in the End field. This will search between
b 7:00 PPM and midnighht on 4/16/20122.

25. Click on
o the Shift droop-down and uncheck
u All, theen check Shiftt 2. Then checck the Use Shiift Start checkbbox.
w return all daata for the shift that started at 7:00 PM, evenn the data that was collected on the next day.
This will
Click View
V Report too render the report.

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26. This reeport shows maachine states for f each machine on the line, represented aas color blocks on a timeline
moving left to right. Itt is a good wayy to see how diifferent machinnes on a line might relate to eeach other, such as a
stoppaage at one macchine causing a starved condition at the nexxt machine dow wnstream. This report showss that
the enntire line was in a CIP (Clean In Place) state for more than half of this shift. That may oor may not be
t poor perforrmance for thiss shift was due to an operational reason, andd not
expectted, but it clearrly shows that the
to faults or other equuipment problem ms.

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27. Let’s see
s if this long CIP time is an anomaly or noot. In the Exploorer, click on My Company > History > Eveent
Summ mary.

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28. When the report rendders, bring up the
t Parameterrs panel. Delette the Event N Name Groupingg and the Sortinng
Param
meter, and channge the Filter parameter
p to filtter on Event N
Name of “CIP”. Click on View
w Report.

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29. The reesulting report shows
s data forr only CIP (Cleaan in Place) evvents. You cann tell by lookingg at the Min.
Duration, Max. Durattion, and Avg. Duration values that the CIP times are highly variable, andd the long CIP times
we saww during our worst
w shift were unusual. Thiss gives us goodd information thhat stabilizing CCIP times shouuld
bring good
g performance returns.

Answer: FactoryTalk k Metrics Eve

ent Data will help you dettermine the rright prioritie
es for reduciing
downtime e and increasing uptime.. In this case
e, addressin g the Oil Failure faults on just 2
machines s will reduce
e the numberr one cause of
o faulted tim
me in the plannt. In additioon, it seems that
the CIP procedures
p should be exa
amined, beca ause this is tthe number one cause o of non-productive
time in th
he plant, and seem to be highly variabble in duratio
on.

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Can mach
hine speed be increased?
After increassing machine upptime, the second component of efficiency to connsider is machinne speed, or the Performance
component of the OEE equaation. This is alsso referred to ass Throughput in ssome of the Repport Expert reports. What we reeally
mean is: Hoow close to theirr ideal speed aree the machines operating?
o
In FactoryTaalk Metrics, macchine speed is exxpressed in term
ms of Ideal Cyclee Time, which is the number of sseconds requiredd to
produce onee part at a machhine under ideal conditions.
c In our application thhis value appearss on the FactoryyTalk View SE sccreen
for each work cell. First andd foremost, the Ideal Cycle Timee for a machine m must be accuratte (and often, Ideeal Cycle Time is
different for different parts produced
p on the same machine). Inaccurate Ideeal Cycle Times will lead to misleeading Performaance
results, and therefore to missleading OEE reesults.

1. Click on
o the Through
hput History report
r in the Reeport Explorer ttree.

2. What you
y see is a standard Througghput report tem mplate that shoows data for the last 5 days foor all work cellss in
w data by Part Id. The simplee simulation thaat we are running in
the plaant. Click on thhe L11Filler woork cell to show
the labb does not varyy the actual cyccle time, so moost of the numbbers shown herre are nearly iddentical.

The fieelds shown in thiss report that we have not seen before
b are:

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 Realized Cycle Time – this is the actual cycle time in seconds. Calculation is Running Time / Total Parts.
Cycle Time Diff. – this is the difference between the Ideal Cycle Time and the Realized Cycle Time in seconds. A negative
number indicates that the machine is operating slower than the Ideal Cycle Time. Calculation is Weighted Average (Ideal
Cycle Time) – Realized Cycle Time.
Cycle Time Diff % - The percentage that the Realized Cycle Time deviates from the Ideal Cycle Time. Calculation is Cycle
Time Diff. / Ideal Cycle Time.

3. If this was data from a real plant, the stability of the Realized Cycle Time would indicate that the machines were
running very consistently. It may be possible to run the machines faster, but that is not clear from the data we
have – we will not find any period of time during which the machines ran any closer to their Ideal Cycle Times. It
might be the case that the Ideal Cycle Times are just set at unrealistic levels. A better scenario might be to just
increase the Ideal Cycle Times to be closer to the Realized Cycle Times, and go after efficiency improvements in
Uptime and Quality instead.
Increasing the Ideal Cycle Times will cause the Throughput, and thus the OEE values to improve, without any change in
plant efficiency. This may represent a more accurate assessment of the plant’s capability. It is important to document that
changes have been made to the application that may impact the metrics going forward, as well as to document
improvements made to plant equipment or processes, so you can determine their impact on the metrics that FactoryTalk
Metrics measures.

4. Go back to the FactoryTalk View SE application and trigger another event on the L11Filler screen.

Answer: FactoryTalk Metrics data indicates that machine speed is quite stable, and if this speed
is acceptable, the Ideal Cycle Times could be adjusted to reflect the desire to maintain current
speeds.

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Can Qualitty be increaseed?
Increasing Quality
Q (by decreeasing Scrap) haas a triple benefiit to the bottom lline – one beneffit is measured bby FactoryTalk M
Metrics,
but the otheer two are not:
 Decreassing scrap increaases performancce by reducing wasted
w machine cycles (which FaactoryTalk Metriics measures)
 Decreassing scrap decreeases material coost (which FactooryTalk Metrics ddoes not measurre)
 There iss another unseenn cost of scrap – if a product is scrapped
s after it has been proceessed by severall machines, the
machinee cycles of the earlier machines are also wasted, although this m may not be meassured by FactoryyTalk Metrics. TThe flip
side to this is if the machhines in a line arre synchronized and product is sscrapped early in the line, then ddownstream machines
may beccome starved forr material and exxperience downttime or wasted m machine cycles.
Decreasing scrap is imperattive to not only inncreasing efficieency, but also to reducing cost aand increasing prrofitability, whichh is
also the whoole objective of increasing
i efficieency in the first place.
p

1. Click on
o the Quality Summary repport in the Repoort Explorer tre e.

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2. Now wew see all the workcells
w sortedd in the order of
o their Quality %, with the woorst performer ffirst. Click on tthe
“+” neext to L13EI to see the detail by Part Id. You can see that on this one maachine, one paart generates 10%
scrap, while the otheer generates alm most zero scraap. Clearly therre are significaant improvemennts that can bee
made here, and theyy appear to be product-specifiic. Even more dramatic is thee zero scrap geenerated by alll of
the maachines in Linee 2. Is Line 2 reeally producingg no scrap? If sso, what can bbe learned from
m Line 2 and appplied
to Linee 1?

3. Collappse the report innto a single linee by clicking onn the “+” sign next to Work ccell to see the overall Qualityy
numbeers for all the work
w cells for thhe past 5 days. The overall Q Quality % is 97..97%, which may sound OK, but at
that raate the plant haas produced ovver 167,000 scrrap parts! Thatt’s a lot of partss, and a lot of m
money. This iss
clearlyy an area wheree HUGE improovements are called c for. Agaiin, FactoryTalkk Metrics cannoot suggest whaat
these improvements should be, butt can provide thhe data to helpp you prioritize the process, inncluding pointinng out
the woorst machine annd product offeenders.

Answer: FactoryTalk
k Metrics data indicates that
t Quality iis a significa
ant problem o
on Line 1 only.

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What is happening
h rig
ght now?

So far we haave only looked at historical dataa logged by FacctoryTalk Metricss. That is invaluaable for analyzinng problems oveer time,
but one of thhe advantages of
o gathering perfformance information from the coontrol system is that the informaation is availablee
immediatelyy, so plant personnel can react too today’s problems today.

1. There are a couple of

o entries in thee Explorer for thhis lab that are useful for lookking at current information. O
Open
the Cu
urrent folder annd click on the L11Filler Dashboard reportt.

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2. This iss a default Dashboard report template
t includded in Report EExpert. It show
ws a variety of ddata available from
FactorryTalk Metrics together
t on one screen. Eacch of the reportt components ((called Widgetss) exposes som me
focuseed data, and all the widgets operate against the same paraameter set, so all the widget ccontents are
synchrronized. As nooted in the headder, this data iss for the Currennt Shift for the L11Filler workk cell, so this is data
that haas been collectted since you began
b this lab. All of the dataa on the dashbooard should bee familiar, as we
have seen
s this kind of
o data in historical reports alrready. This infformation givess an operator aan excellent
overview of how this machine has been b performinng on this shift.
Becausse the data to prroduce this and all
a Report Experrt reports residess in a database, there is always some latency beetween
somethhing happening ini the control sysstem and that daata appearing in a Report Experrt report. You may notice a delaay of a
minute or two before a change in the FactoryTalk
F View
w SE screen is reeflected in a Repport Expert repoort.

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3. Click ono the Parametters button to see
s the parameeter set used too produce this report. From tthe Plant Modeel
param meter you can sees that just L11Filler is selected. The Grouuping is a speciial one for the Dashboard repport
templaate that works with
w all of the widgets,
w so thiss grouping paraameter cannot be changed. N Notice in the
Date/T Time/Shift paraameter that Currrent Shift is seelected. This iss a special timee filter that retuurns just data frrom
a still in progrress. We have not spent mucch time during tthis lab on the Date/Time/Shiift
shift innstances that are
param meters, and theyy are really quite powerful, soo take a minutee and browse thhe options thatt are offered for time
filtering. This is coveered in more deetail in the Repport Expert Advvanced Lab.

4. Click on
o the Exploreer button in the Report Expertt toolbar and seelect the Machhine States repport.

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5. This reeport template graphically shoows the historyy of machine sttates for all work cells in a linee. It is especially
valuabble for understaanding how woork cells might interact with eaach other on a Line. In this caase we are loooking
at currrent data for thee last 30 minuttes, so this dataa would be verry useful for ann operator or linne supervisor. We
have only
o been caussing events to occur o at the L11Filler work ceell, so all of the others are in aan uninterrupteed
Runninng state. Remember that thee L1S work cell is a special onne that monitorrs both the L11Filter and
L15CaasePacker macchines, so in this case it will match
m the behaavior of the L11Filter work cell.
If data collection has been running for more than 30 minutes, you can use the left arroow keys to scroll back in time.
At the bottom
b of the Linne 1 section of thhe report, click on
o the “+” next too Click to expannd state detailss.

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6. This shows the detailed Machine State data for Liine 1 for the paast 30 minutes..

Any of the Report

R Expert report templates can
c be matched with parameterss that display currrent data, but thhe two reports thhat we
have examined are especiaally suited to the needs of an opeerator or line suppervisor who is innterested in currrent performancee.

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Using FacctoryTalk VaantagePoint EMI
E to visualize FactoryTTalk Metrics ddata

Another wayy to look at data from FactoryTaalk Metrics is usinng FactoryTalk V

VantagePoint EM
MI, which is bundled with FactorryTalk
Metrics 10.00 systems.
E is a business intelligence soolution for manuffacturing that inteegrates informattion from
FactoryTalkk VantagePoint EMI
manufacturing and businesss systems and presents
p the information in a mannufacturing portaal.
A FactoryTaalk Metrics Connnector for FactorryTalk VantageP Point EMI is availlable to FactoryTTalk Metrics cusstomers. So all oof the
data that is collected by FacctoryTalk Metricss can be exposeed in FactoryTalkk VantagePoint E EMI, where it caan be integrated with
data from otther manufacturiing and businesss system. The FactoryTalk Mettrics connector ffor VantagePoint is covered in detail in
a FactoryTaalk Metrics Advanced Lab.

1. On Image 1, run the VantagePoint Portal. Start > All Programss > Rockwell S Software > FaactoryTalk
VantagePoint > Porrtal. When thee Portal opens, click on Repo rts in the toolbbar and choosee MyEnterprisee.

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2. In the MyEnterprise > Public tree, you
y will find all of the Report E Expert reports from the FactooryTalk Metricss
applicaation, along witth many reportts that show daata from other pparts of the VantagePoint moodel. Locate the
MyCompany sectionn of the tree, annd click on Currrent > L11Filller Dashboardd to display thee report that wee just
saw a few minutes ago.

3. There is a new reporrt here that is created

c in FactooryTalk VantaggePoint EMI annd included withh the FactoryTTalk
Metriccs connector. Click
C on Workccell Current Sh hift.

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4. This reeport is designeed to display data from any work
w cell defineed in FactoryTaalk Metrics. Chhoose L11Filleer from
the listt of WorkCells (the name shoown here is longger, so you cann see the workk cell’s position in the Plant Model),
and thhen click Generrate Report.

5. You will
w see a dashbboard showing current shift infformation for thhe L11Filler woork cell. On onne screen theree are
gaugees for OEE and its 3 componeents, Part counts, key timers, and current staate informationn. The data w will
refreshh every 30 seconds. This dasshboard was constructed
c usi ng Xcelsius. CClick on the Chaart button.

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6. An houurly chart of OE
EE and its 3 coomponents is displayed
d for the current shift. Click on the Chart button aggain to
close it.
i

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7. You caan drill-throughh each of the 4 gauges on thee dashboard to see another reeport. Click onn the OEE (%)
gaugee. This Excel reeport is similar to the Chart poop-up we just ssaw, but displaays data for thee last 24 hours. In
our caase the data loooks a little strannge, because there was data already in the database through 18:00
yesterrday, and then a gap where thhere is no data until you begaan this lab. Clicck on the Drill to Dashboardd
Workccell link to return to the dashbboard.

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8. Click on
o the Availability (%) gaugee. This will opeen an Excel repport that showss a graphical viiew of the Evennts
that haave occurred at
a this work cell during the currrent shift. Theese are the eveents that you triiggered on the HMI
screenn for work cell L11Filler.
L Notee that there aree multiple tabs at the bottom oof the report. If you click on oone of
those tabs, you will see
s this same data
d in a differeent format and level of detail. Click on Drill to Dashboardd
Workccell to return too the dashboarrd.

9. If you would like, youu can click on the other two gaauges (Perform
mance (%) and Quality (%))) to see the dettail
reportss. You can close the VantaagePoint Portall, or simply retuurn to the Repoort Expert pagge in Internet
Explorrer, which shouuld still be openn.

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How do we
w get the rig
ght informatio
on to the righ
ht people?

So far we haave done a lot of ad-hoc reportinng, but we have not saved any oof the reports wee have used so tthey can be usedd
again.
Based on ouur research so faar, a decision haas been made byy plant managem ment to prioritizee fixing the Oil Faailure problems in the
plant. The maintenance
m maanager wants a report
r that will traack the effectiveeness of the projject. So we will create a report tto
track Oil Failures over time, and add it to thee Explorer tree sos the maintenannce manager caan run it as needded. The mainteenance
manager will not need any special
s software on his computeer, just Internet E Explorer and the Report Expert hhome page addrress.

1. Go back to the Repoort Expert pagee in Internet Expplorer, and clicck on Event Chhart L11Filler rreport in the
Explorrer tree.

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2. Click on
o Parameterss to see the Paarameters window. We will ch ange the Parameters to creaate the report thhat the
mainteenance manager wants. Set the Grouping to Date and deelete the otheer grouping. IIn the Sorting
parammeter, delete all entries. This will sort the report by the groouping values ((Date). In the P
Plant Model
parammeter, select all the machinees in Line 1 and Line 2, exceept for L1S annd L2S to show w all machines. In the
Filtering parameter, select Event Name
N and chooose Oil Failuree. Click View Report.

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3. Now thhe Report show ws us downtime due to Oil Faailure by date, sso we can see the trend of doowntime due too this
fault over time. This will satisfy thee maintenance manger’s needd for a report thhat tracks Oil FFailures over tim
me.

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4. Let’s save
s this Parammeter Set so we can use it forr the maintenannce manager’ss report. Go to the Parameterr
windoww and in the fieeld Edit Param
meter Set Name enter Lab 1 O Oil Failure by Date. Click onn Save As to ssave
the Paarameter Set.

5. We muust go to the Administration

A page
p to create a new entry in the Explorer trree. This is a fuunction that maay only
be perrformed by useers with Administrator rights. Click on the Addministrator bbutton in the Reeport Expert tooolbar.

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6. When the window apppears, click onn the Report Explorer tab.

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7. Collappse the root-levvel folders in the tree to make navigating it eeasier. Locate the My Company folder andd
right-cclick on it. Select New Child d Tree Item to create a new eentry in this foldder.

8. Fill in the
t properties in the right pannel. Name the folder Maintennance. Click S
Save.

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9. Right-click on the Maaintenance foldder and select New
N Child Treee Item.

10. Fill in the

t properties as
a shown heree. Make sure you
y choose EveentChart as thhe report and thhe Lab 1 Oil Faailure
by Date parameter set,
s which is thhe one we just created. Clickk on Save.

11. Click the

t Explorer tooolbar button too return to the main
m Report Exxpert screen.

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12. In the Report Exploreer, expand the My Companyy and Maintenaance folders too see the new rreport entry. C
Click
on Oil Failures by Date.
D

13. The neew report will reender. Note hoow the Report Explorer entryy name is used as the title of tthe report. Now
w
mainteenance personnel can accesss this report whhenever they w want to assess tthe progress oof their efforts too
reducee Oil Failures.

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Summary

We started this lab with a list of questions we wanted to answer about the performance of our simulated plant. Using the data
collected by FactoryTalk Metrics and the Report Expert and FactoryTalk VantagePoint EMI reporting environments, we
answered them all. This is probably not surprising since a hands-on lab is a controlled environment, and we certainly could have
“stacked the deck” so that the questions were easy to answer. Hopefully the questions that were chosen are representative of
“real world” questions that manufacturers do need to answer to improve their operations and to reduce costs, and they need to
answer them quickly, accurately, and on demand.
As has been said earlier, this lab has been mostly an ad-hoc journey through the capabilities of Report Expert, although the
capability to create permanent reports that can be used over and over was covered. Naturally, all users are not expected to be
able to take full advantage of the ad-hoc reporting capabilities that Report Expert offers, but the idea was to expose the flexibility
that does exist.

To review, the questions that we answered in the lab were:

1. How well has the plant been performing?
 What are some of the ways we can measure performance?
 What is the worst performing line?
 What is the worst performing machine?
 What is the worst performing shift?
 What is the worst performing part produced?
 Who is the worst performing operator?
2. How can the plant’s performance be improved?
 How can we start reducing downtime (or lost time)?
 Can machine speed be increased?
 Can Quality be improved?
3. What is happening right now?
4. How do we get the right information to the right people?

We have also shown some specific features of Report Expert:

 The ability to dynamically change parameters for ad-hoc reporting
 The ability to change reports by altering Grouping
 The ability to Sort data in reports
 The ability to filter data using the Time/Date/Shift, Plant Model, Top N, and most data fields
 The ability to Drill-down and Drill-up within a report
 The ability to Drill-through data values in reports to show more detailed information
 The ability to export report data to Excel
 The ability to Save parameter sets for later use

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  The ability to add reports to the Report Explorer
 The ability to summarize data based on any grouping field
 The ability to dice and slice data on multiple dimensions of context
 The ability to use multiple parameter sets against a single report to change both its content an appearance
 The ability to use a single parameter set with multiple reports
We also introduced the FactoryTalk Metrics connector for FactoryTalk VantagePoint EMI, and demonstrated how the same
reporting capabilities, plus some additional ones, can be accessed using the VantagePoint Portal.

We urge you to continue to learn more about FactoryTalk Metrics, Report Expert and FactoryTalk VantagePoint EMI by taking
one of the Advanced Labs that are offered.

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Appendix A – Report Template Columns and Drill-Through Destinations

The following table lists the Data Columns contained in each of the standard Report Expert Report Templates. It also lists the
drill-though destinations for each of the Data Columns, where appropriate.
The drill-through hierarchy is the same for all Report Templates where drill-through is supported:
 Site
 Area
 Line
 Work Cell
 Month
 Week
 Day
 Shift
 Hour

Report Template Data Column Drill-Through Report Template Destination

Dashboard All None
EventChart Event Count Event Chart
Total Duration Event Chart
Min Duration Event Chart
Max Duration Event Chart
Avg Duration Event Chart
Detail Event Detail
EventConfiguration All None
EventDetail All None
EventHistoryString All None
EventHistoryValue All None
EventOverview All None
EventSummary Event Count Event Summary
Total Duration Event Summary
Min. Duration Event Summary
Max Duration Event Summary
Avg. Duration Event Summary
Event Detail Event Detail
Fault Running Time Fault
Fault Time Fault
Fault Count Fault
MTBF Fault

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Report Template Data Column Drill-Through Report Template Destination
MTTR Fault
Faults per Hour Fault
Fault % Fault
Detail Event Summary
Performance Uptime % Uptime
Throughput % Throughput
Quality % Quality
OEE % Performance
Production Good Parts Production
Scrap Parts Quality
Total Parts Production
Ideal Parts Production
Ideal % Production
Scrap % Production
Running Time Uptime
Uptime % Uptime
ProductionOverview Uptime % Uptime
Throughput % Throughput
Quality % Quality
OEE % Performance
Available Time Production Overview
Downtime Production Overview
Running Time Production Overview
Good Parts Production Overview
Scrap Parts Quality
Total Parts Production
Ideal Parts Production
Scheduled Unavailable Production Overview
Time
Faults Faults
TEEP Performance
Quality Good Parts Quality
Scrap Parts Quality
Quality % Quality
RootCauseAnalysis None None
StateDetail Workcell None
Shift None
Shift Start None

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Report Template Data Column Drill-Through Report Template Destination
State Name None
Start Time None
End Time None
Duration None
StateSummary State Count State Summary
Total Duration State Summary
Min Duration State Summary
Max Duration State Summary
Avg Duration State Summary
Detail State Detail
Throughput Total Parts Throughput
Running Time Throughput
Realized Cycle Time Throughput
Cycle Time Diff Throughput
Cycle Time Diff % Throughput
Throughput % Throughput
Uptime Running Time Uptime
Available Time Uptime
Downtime Uptime
Uptime % Uptime

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 Notes

Puublication XXXX-X
XX###X-EN-P — Month
M Year 102 of 102 Copyright© 2011 Rockwell Automation, Inc. All rights reserved.
Suupersedes Publicatioon XXXX-XX###X-E
EN-P — Month Year