In today's world of fully automated production, it can be difficult to turn process data into useful information. One way of doing this is by using Siemens WinCC Performance Monitor in conjunction with Simatic Information Server. In this series we will cover the basics of these tools their benefits, details on implementation, and how to quickly realize the return on your investment.

Turning Data into Information

Many manufacturing companies cannot easily assess the health of their plants. This is rarely due to a lack of data. Process Historians collect real-time data and can show trends over time. Quality control data can be compared to those trends, and even some KPIs can be calculated for the process as a whole. But, this system breaks down when raw data is the only resource available to provide the necessary insight to answer questions about operations.

Data fails to take into account micro-level details affecting macro-level performance. For example, with raw data alone it can be difficult to determine which machines are causing the most downtime, where bottlenecks are in the process and where quality losses are greatest. Determining the top ten causes of downtime first requires collecting all of the data in one location, summing the downtime for all pieces of equipment, and ordering the list. If you are lucky, you might be able to get all of this done before the phone rings with other distractions.

So, how do we track the processes, find the major issues, and get them resolved? One way is to use performance management systems such as WinCC Performance Manager and Simatic Information Server. These systems take the process data you are already collecting and provide the context necessary for the data to be useful as a decision making tool.

Deciding to Do Things Differently

The decision to implement a performance monitoring system can seem daunting. The cost of buying the software, the time involved in configuring it, learning a new system, and then integrating it into your workflow. While there are some costs associated with the system both in terms of time and resources, it can have a direct impact on your bottom line. One simple example is to use the tools to identify and reduce the top three reasons for downtime in your plant—thus automatically increasing productivity.

Our customers have made even more gains in decreased processing time by identifying bottlenecks and reducing re-work/scrap by identifying faulty equipment. In our Boss Mode series we will focus on Siemens' WinCC Performance Monitor and Simatic Information Server. We will answer common questions about what these tools have to offer and discuss of the direct benefits our customers have found when using them. If you are looking at similar solutions from other companies, we will cover continue to cover those in later posts.

To summarize, performance management systems give you the ability to ask questions about your operation while providing the information you need to answer those questions and prioritize improvements. They give you an honest assessment of your plant's health. While this information can be difficult to stomach, if your plant needs some help wouldn't you want to know exactly what to fix to make it better?

Check out more in our Boss Mode Series! Want more info? See our Ultimate Manufacturing Execution System Guide.