Machine Builder (OEM) Solutions
What Matters
Information Matters
Today's machines generate incredible amounts of raw data — whether it be the number of parts scrapped during a shift or the number of parts built. That data, when put into the proper format and into the appropriate hands, can be turned into useful information to improve business processes.
New business realities like time-to-market pressures and regulatory compliance are driving OEMs to build machines with integrated control and information systems. Creating an integrated environment where information can be easily accessed from the automation system and viewed in the correct context enables better, faster decision-making.
The Right Mindset and the Right Tools
Many OEMs are interested in integrating control and information in their machines to improve the end customer's productivity. With the right mindset and preparation, the OEM is already halfway there. Integrating control and information systems then requires careful deployment.
At EAGLE Technologies Group, an OEM that manufactures assembly cells for automotive users, the system's newly integrated communications structure uses the Rockwell Automation FactoryTalk production and performance suite for information integration and the Logix platform for control. Triggered by an automotive customer's request for a large new assembly system consisting of 800 linear feet of conveyor and 20 automated work cells in a timeframe of 28 weeks, EAGLE not only met the end customer demand with the integration, but additionally streamlined their system engineering by 12 percent and shortened average system delivery time by 4 weeks.
Integrated Architecture: Uniting Automation and Information
For ERP and supply chain systems to deliver maximum value, they need regular care and feeding of information emanating from their counterparts at the automation layer. With its Integrated Architecture, Rockwell Automation combines the Logix Control Platform and FactoryTalk production and performance management software suite into an attractive proposition for OEMs looking to convert manufacturing data into valuable business information.
The Logix Control Platform provides fully integrated, scalable solutions for the wide range of automation disciplines including discrete, motion, process control, drive control, safety and information using a single control platform. The platform is information-enabled, as it is designed to be easily integrated with a customer's information systems through the FactoryTalk suite to dramatically simplify data collection.
FactoryTalk: Leveraging Plant-Floor Information
The FactoryTalk suite gives OEMs expanded insight into their production processes, enabling them to execute business strategies that drive competitive advantage. The software consists of multiple production disciplines including: performance and visibility; production management; asset management; quality and compliance; data management; and design and configuration.
FactoryTalk helps OEMs information-enable machines or skids in advance with modular software components, making it significantly faster and more cost-effective for end users to incorporate new assets into a plant's pre-existing "information environment".
"We were tasked with building a large and complex system capable of collecting extensive product information during the assembly process," Zimanski said. "Within six weeks working with Rockwell Automation, we had created the entire system specifications outlining the specific type of data to be collected, how that data would be protected, and how it could be used," said Zimanski. "Typically it would take us 12 weeks to produce specifications that were this detailed."
By combining a highly flexible, modular control platform with an integrated suite of plant-wide information software, Rockwell Automation delivers powerful information-enabled solutions for today's machine builders.
Product Highlights
FactoryTalk Disciplines
The FactoryTalk Integrated Production and Performance Suite create a single, clear brand identity for Rockwell Software's systems-oriented software offerings. The FactoryTalk suite spans a broad range of interrelated production disciplines common to most manufacturing operations. FactoryTalk incorporates six production disciplines: Performance and Visibility, Production Management, Quality and Compliance, Data Management, Asset Management, and Design and Configuration.
Performance and Visibility — Presents a window into the process so you can make better decisions. Includes reporting and analysis tools, role-based operator interfaces and dashboards, key performance indicators (KPI) and situational display at machine, line, plant and enterprise levels. FactoryTalk products available in this category include FactoryTalk Metrics, FactoryTalk View and FactoryTalk Portal.
Production Management — Offers real-time coordination across your plant-wide production processes. Includes order scheduling and execution, tracking and genealogy, resource management and multi-site production synchronization. FactoryTalk products in this discipline include FactoryTalk Batch, FactoryTalk Scheduler and FactoryTalk ProductionCentre.
Asset Management — Optimizes maintenance and plant operations to improve your resource availability. Includes products for risk mitigation and change management procedures, comprehensive diagnostics and device configuration, calibration and real-time monitoring, and auditing of operator actions and device health. FactoryTalk offerings here include FactoryTalk Security and FactoryTalk AssetCentre.
Quality and Compliance — Ensures your operational processes and procedures meet standards or specifications. Products in this discipline simplify regulatory compliance and reporting, provide an automated proactive quality environment, improve first-pass quality, and enhance product and process consistency.
Data Management — Tools and methods to use for collecting, transforming and integrating production information. Products enable: event, process or master data collection and storage; integration and workflow across disparate systems; and organization, synchronization, archival and aggregation of data. Products in this discipline include FactoryTalk Historian, FactoryTalk Gateway, FactoryTalk Integrator and FactoryTalk Transaction Manager.
Design and Configuration — Integrated environments for creating, modelling and programming your production processes. Products allow: automation control programming; setup and propagation of reusable equipment; and rapid process development, simulation and deployment.