SIMATIC HMI WinCC V7.0 System Description - DCE FEL ČVUT v ...

3.3 Plant Intelligence Options SIMATIC WinCC
Figure 93 Causal factor tree
3. For productivity, you define relevant operating states
such as "Unplanned cleaning" and "Fault". You assign
these operating states to specific colors for easy identification
and up to ten status families such as Maintenance
and Fault. For short downtimes, i.e., Microstops, which
do not last as long as machine downtimes, you define a
threshold value in the equipment and machine units.
4. Finally, for each plant, you create a causal factor tree
with a bi-level causal factor hierarchy:
– Time to be monitored, for example, "Unplanned
downtime"
– Operating state as the cause, for example,
"Unplanned cleaning"
– Operating state as the root cause, for example,
"Fault"
In the status table, all combinations of causal factors in
the controller are automatically generated with a status
number, which you can modify afterward:
– "0035: Unplanned downtime for unplanned cleaning
due to a fault."
– "0036: Planned downtime for planned cleaning."
– Etc.
5. You define the equipment and machine units and the
required production speed, for example, 400 pieces per
hour. If, after 5 hours, the unit has only produced 1,000
pieces, the target achievement is 50%. Production
speed can be dynamized by means of a tag: If larger
palettes are processed following a format change, the
production speed changes accordingly.
6. In the formula generator, you use point-and-click functionality
to link the defined times, for example,
"Unplanned downtime" and the number of pieces to the
formula variables for performance indicator, for example,
"Availability", which is then calculated when queried.
Complex evaluations affect performance.
Examples of evaluations:
– Downtime management Availability describes the
ratio of the actual operating time to the planned,
available production time.
– Availability A: The machine is operational in terms of
mechanics and electricity, but the material is missing.
– Availability B: The machine is operational and the
material is available.
– Production analyses: The performance rate
describes the actual throughput of a machine compared
to the ideal throughput time.
– Quality management: The quality rate describes the
percentage of error-free production parts.
Many more formulas are predefined; however, you can
adapt these for your requirements:
– OEE = Availability * Performance * Quality
– Mean Time Between Failures MTBF
– Mean Time to Repair MTTR
– Productive Time, Cycle Time
– Downtime Loss, Speed Loss
– Mean Time Between Assists MTBA, Mean Time To
Assists MTTA
– Total Effective Equipment Productivity TEEP,
Effective Output
– Maintenance, Utilization
– Change Over, Occurrence
– Calculated Time
– TEEP = Equipment Utilization x Performance Rate x
Quality Rate
By linking defined times, counters, or status families and
events from the predefined formulas, you create a new
user-defined formula for a performance indicator. For
complex projects, you can also combine formulas in
Microsoft Excel and reimport them to DowntimeMonitor.
7. The automation system is linked by a WinCC status tag,
which contains the status number as a current value.
Specific counters can also be linked, for example,
number of items.
Figure 94 Pareto chart of KPIs
SIMATIC WinCC System Description
60 A1900-L531-B996-X-7600, 09/2008