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Accelerating the Performance of Your Production Enterprise

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BUILDING FOR SPEED & AGILITY Power up with real-time operations management tools & techniques. CASE STUDY: CITROSUCO Orange juice producer squeezes more efficiency out of production. CASE STUDY: DB BREWERIES Brewery taps Wonderware to locate and solve problems.

Competing in an increasingly fast-moving, global market is all about tightly integrating manufacturing operations with the rest of the business. Implementing a flexible plant software platform that provides access to real-time manufacturing intelligence is the only way to win the race.
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SPEED & AGILITY

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Manufacturers can synchronize manufacturing operations with the demands of the business by utilizing Real-Time Operations Management tools and techniques.
There are two dimensions: First, how good is my data and, second, how real-time is my data? Wonderwares Bhattacharya
they need an up-to-the-minute understanding of whats going on throughout the global organization. Information from manufacturing is needed in order to make a decision about what can be made, where to make it, and the overall design of the supply network, Smith explains. For example, if I want to serve southern Asia, can I use existing capacity, do I need additional capacity, which facilities can serve the market most profitably? These are important questions that need real-time answers, she says. Plant-to-enterprise systems integration has long been held up as the way to link manufacturing operations with the rest of the enterprise. And, indeed, it is a slice of the solution. But now, manu-

n manufacturing these days, everything hinges on perfect timing being in the right place at the right time to make a deal, completing a project on time, and delivering product just in time to meet market needs. Speed, of course, is a major element in the strategy of any business. But manufacturers cant compete on speed alone. Thats because manufacturing is not simply a race to the finish line. Rather its much more like an Olympic contest where the winning strategy is a result of the perfect synchronization of mind, body, and spirit. Of course, manufacturing is much more complex than racing around a track. It requires companies to distribute production around the world while keeping supply networks lean. The only way to achieve this, say experts, is to tightly synchronize manufacturing operations with the rest of the business. In fact, manufacturing has entered the era of what AMR Research Inc. calls demand-driven transformation. It is the need to connect manufacturing in a very substantial way into the business process backbone, says Alison Smith, a research director at AMR. In other words, manufacturers must be able to quickly adapt their processes to shifts in the market. And, in order to do this,

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facturers are realizing they need a more comprehensive remedy that will aid them through this demand-driven transformation. The complexity of the situation requires an architecture that enables flexible interoperability, applications that provide visibility, and a technology and partner network that creates natural agility. More important, it all has to happen in real time. Thats where Wonderware, a business unit of Invensys, steps in. Wonderware, the market leader in operations management software, offers a portfolio of products focused on powering operations management in real time. Its technology can also integrate information from multiple data sources, helping manufacturers drive speed, agility, efficiency, quality, and performance across discrete, process, and hybrid manufacturing operations. According to Sudipta Bhattacharya, president of Wonderware, most of the real-time information that companies need to access in order to drive decisions comes directly from the plant floor. When we talk about effectively managing information, there are two dimensions, Bhattacharya says. First, how good is my data and, second, how real-time is my data? Wonderware software paves the way for companies to access and execute on that information. It includes Supervisory HMI, GeoSCADA, Production Management/MES, Performance Management/Enterprise Manufacturing Intelligence (EMI), and ArchestrA the technology foundation that enables integration with asset management, supply chains, and ERP applications. Collectively, this software portfolio forms the foundation to empower plant workers by enabling them to easily access data, regardless of where it resides. That, Bhattacharya says, is something that Wonderware does better than anyone else in the industry, and has for a long time. Indeed, Wonderware has always been a hardware-independent software company. Its applications are designed to work with any control architecture and any device. Wonderware has a long history as a software company selling platform-independent HMI, AMRs Smith says. So they had a head start on the market ... I have to say, when you look at the set of devices they can connect to, its mind-blowing. Wonderware has also established a strong circle of partners in the form of distributors and systems integrators located in more than 100 countries around the world. These local and regional service providers, which reach 3,500 or more companies globally, are backed by the expertise of the Wonderware Global Customer Support & Service team. As a result of this partner ecosystem, we have what we call the real-time platform on the plant floor, and we have the widest reach, Bhattacharya says. This is important in todays global economy where manufacturers have facilities located around the world. Now, not only is Wonderware technology scalable, but so, too, is its service and support business model. To that end, Wonderware provides its customers in a variety of industries including food and beverage, power, water and wastewater, facilities management, transportation, upstream oil and gas, mining, metals, and others with the ability to orchestrate information management and accelerate decision-making. Real-time operations management is the ability of any company to access and execute information to drive operations

Manufacturing Operations Market Growth

ccording to AMR Research Inc., the manufacturing operations software application market is divided into three major revenue subsegments: enterprise asset management (EAM); enterprise manufacturing intelligence (EMI, increasingly referred to as operations intelligence); and manufacturing execution and management (including MES quality processes, in-plant production performance management, batch and recipe management, etc.). The manufacturing operations software application market will experience a five-year 13% CAGR, reaching more than $8 billion in revenue by 2011. $6.5 billion $7.4 billion

$8.3 billion

$4.6 billion

$5.1 billion

$5.8 billion

2006
*Forecast

2007

2008*

2009*

2010*

2011*

Source: The Manufacturing Operations Software Application Market Sizing Report, 2006-2011. AMR Research Inc., 2007

across an extended supply chain network, Bhattacharya says.

Real-Time Operations on the Rise

Manufacturing operations software, as defined by AMR, includes three main categories: enterprise asset management (EAM), enterprise manufacturing intelligence (EMI), and manufacturing execution systems (MES). Collectively, these applications, which generated $5.1 billion in worldwide revenue in 2007, are expected to grow to represent an $8 billion market by 2011, AMR Research predicts (see table, above). The reason for the upsurge is that many manufacturers are looking beyond their ERP systems to help them close the information gap between the plant and the enterprise. SAP, for example, is working closely with Wonderware to bring together core strengths that provide a better solution that can be deployed faster at the customer site. The two companies are work-

We bring a rich set of tools ... So when you think of the analytics side, think about visibility around data. Microsofts Colyer
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ing on delivering software capability that effectively helps each end of the organization business and manufacturing interoperate almost transparently. Traditionally, Wonderware focused on plant-level execution while SAP focused on enterprise business processes, says Vivek Bapat, SAPs vice president, suite solutions marketing, product, supply, and manufacturing solutions. In the new world of manufacturing operations management, both companies are working jointly to close the gap between the plant and the enterprise by providing new solutions that combine visibility and process orchestration. The goal is to ensure that mutual customers are able to seamlessly integrate manufacturing execution into the business process.

Visualizing the Future

he best way to understand Wonderware technology is to describe its main purpose in the plant. That can be summed up in one word: visualization. We have enterprise-wide visualization so that you can see data, whether its real-time or historical data, says Rashesh Mody, Wonderware vice president of product management. We can get all of that information displayed in one spot. That is accomplished thanks to a flexible framework called the ArchestrA architecture that underlies Wonderware applications. The platform which Invensys has invested more than $60 million in developing is built to lower customers integration costs by enabling connectivity to any control architecture or enterprise application used in discrete, hybrid, and process industries. Using ArchestrA technology, Wonderware has developed key applications to provide a window of insight. Collectively called Wonderware System Platform, its a system-based license that includes all the capabilities needed by a manufacturer. Its a universal platform for many different types of applications, such as supervisory control, HMI, GeoSCADA, historian, production Rashesh Mody management (MES), EMI, and Web portal applications. This information is deliverable to an end user via any client desktop or mobile device. The approach is based on a service model that allows for interoperability among all of the applications. All of the key services you need are built-in, and all the services interact with each other, which is a key part of the architecture, Mody says. A distinction of the Wonderware technology is its ability to access data in real time, providing a view into what is happening now, in addition to what happened in the past. Data connectivity occurs via open connectivity (OPC), and Wonderware technology also leverages industry standards, such as the ISA-88 batch standard and ISA-95 for plant-to-enterprise integration. Another important aspect of the Wonderware technology strategy is an object model that represents plant assets. Adding capability to the model is as easy as inserting a new object; theres no need to deal with complex code. You can just change an object template, and any part of the application using that template is also changed, Mody says. The real power is in the ability to standardize operations, integrate all data, and the flexibility to change any aspect of the application easily and with minimal engineering effort. Wonderware continues to build out functionality in all of its applications, paying specific attention to sophisticated analytics that will help users understand how information from the plant will impact the entire organization. So, while visualization is a key element of the Wonderware technology, the architecture enables so much more than just seeing. It provides the ability to do things based on this new information, such as improving operations, taking advantage of new opportunities, and becoming more competitive. And, finally, it empowers people with the right information at the right time and with context in the right form they need it in.

In addition, Wonderware is the worlds leading industrial software business, with more than 500,000 active software licensees around the globe. This represents approximately one-third of the worlds industrial facilities. So its no surprise that SAP, the predominant ERP supplier, and Wonderware share many of the same customers. And many of them are looking to tie the two environments together, says Tim Fief, chief software architect at Progressive Software Solutions (PS2), a Wonderware systems integration partner. More companies want to use Wonderware for integration into ERP than ever before. But the value-add offered by Wonderware, Fief says, goes beyond the ability to easily integrate plant floor and enterprise systems. Wonderware also adds a layer of redundancy and availability around control and safety systems, he says. Another key Wonderware partner is Microsoft. Wonderware has built its applications on Microsoft technology, including .NET at the foundation layer, SharePoint Portal Server to enable collaboration, and BizTalk Server for integration and scalability. The company also leverages the analysis and reporting services built within SQL Server. Microsoft is working with key partners, and Wonderware is one of our primary partners on the manufacturing operations end, says Chris Colyer, Microsofts worldwide director, manufacturing operations strategy. Microsoft helps companies build out a data strategy by making it easy for users to manipulate and manage data as it relates to business. We bring a rich set of tools and a technology platform. ... So when you think about the analytics side, think about visibility around data, Colyer says.

Making Sense of the Data

Indeed, visibility into real-time data is, in many ways, the key to making a manufacturing business more responsive. So its not surprising that EMI (also known as operational intelligence) applications are suddenly coming together with MES. And Wonderware is ahead of the market curve on this as well, as a result of its 2007 acquisition of Cimnet, a leading MES software solutions company whose offerings include intelligence applications. Wonderware has also done extensive development work to tie some of its applications together with SAPs Manufacturing Integration and Intelligence (SAP MII technology). MII leverages Web services to extract data from multiple sources, aggregating the data at the server, transforming it into business context, and personalizing it for delivery to the appropriate end user. This allows manufacturers to more easily and quickly take action on the operational insights delivered by EMI software. Its great to say you have access to real-time information, but you also need the ability to execute, Wonderwares Bhattacharya says. These are the types of developments that will drive the next phase of operational efficiency, say industry observers. Successful manufacturers in the future will need to master the art of integrating business processes that transcend their enterprise, i.e., across their network of business partners, including suppliers, contractors, and outsourcers to enable network-wide responsiveness and operational excellence, SAPs Bapat says. Next-generation plant to enterprise solutions must support this requirement. To deliver a technology solution that incorporates business

processes focusing on best practices around operational excellence, becoming more responsive to the demands of the supply networks, or linking design and manufacturing together the architecture underneath needs to be flexible. Translation: Solutions must be built using services-oriented architecture (SOA) and composite applications. Part of the reason that Wonderware applications are so nimble has to do with its underlying ArchestrA infrastructure, a servicesoriented layer that enhances flexibility. The way that Wonderware technology is built makes it well-suited for building composite applications, says AMRs Smith. This is an area that more customers are craving, and the company that can deliver what end users want will be the company with the winning strategy. Whoever can appeal to the way that users work and get

that user interface to a mobile device just look at the work Microsoft is doing in the mobility area thats the company that will explode with innovation, Smith claims. Wonderware, as a software company that is not tied to any specific control architecture, has the ability to be nimble, agile, and respond rapidly to customer needs. In this world of demand-driven transformations, there is a need for adaptive business networks. And you cant adapt processes until you understand how all of the cogs fit into the big picture, Smith says. Meanwhile, Wonderware continues to accelerate its own efforts to ensure that it has a solution for every customer problem. This is a journey, not a destination, Bhattacharya says. As long as customer needs change, we will continue to serve their needs.

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Squeezing More Efficiency Out of Production

Orange juice producer turns to Wonderware for integrated plant-enterprise data and real-time access over the Web to ensure fast, efficient production.
addition, Citrosuco recently adopted the Wonderware Information Server as a way to aggregate and present plant production and performance data in real time over the Web. Many of the manufacturing processes are tied to SAP, but we need to get information about the process from the automation system, explains Milton Bilar Montero, a project engineer at Citrosuco. We chose the Wonderware Application Server as the platform to provide this communication with SAP.

itrosuco, a business unit of Fischer Group, is one of the worlds largest orange juice producers. It operates four plants in Brazil a country where 80% of the orange juice consumed in the world originates as well as one processing facility in Lake Wales, FL. Production speed and product quality are two important aspects of the business, and the company is always seeking ways to fine-tune each step of the process, whether it is receiving raw materials, monitoring variables while producing a batch, or shipping the end product to distribution terminals. To gain total control over the many steps of its process, Citrosuco realized it needed to tie information from the plant floor to its enterprise business system. To accomplish that formidable task, the company turned to two of its key technology partners, Wonderware and SAP. Years ago, Citrosuco decided to standardize on SAPs R/3, which included a manufacturing module. More recently, the company began to leverage its use of Wonderware applications, including InTouch HMI and the Wonderware Historian software, to provide a deeper view into what is happening on the plant floor. In

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Like any manufacturer operating in a highly regulated industry, Citrosuco must be able to trace every lot of raw material, which means it needs to have the complete history on each batch, and have it available for many years. Thats where the Wonderware Historian application helps. And, like any manufacturer in any industry, Citrosuco strives to be the best at what it does producing high-quality orange juice at high speed and it is leveraging Wonderware Information Server to help. We need a system that can help us deal with a lot of information, Montero says. More important, we must be sure the information is correct. The Wonderware applications extract information from the source at the plant, which ensures the accuracy of the information, he says. Prior to tapping into the power of the Wonderware Information Server, Citrosuco tried to tie its PLCs and process control directly to the ERP system. But this information was very restricted to the process, Montero says. Now, the company can expand the breadth of interaction to include purchasing and receiving in order to calculate how much raw material is coming in from the orchards and to

quickly make the correct payments to the fruit producers, according to Montero. Integration between plant and enterprise applications occurs via standard Web services, XML, and SAPs Exchange Infrastructure (XI) software. Wonderware Information Server, which acts as a portal providing plant managers and corporate executives with visibility into the process, interoperates easily with the Web services environment. The Wonderware Information Server tracks KPIs for each step in the process so that managers can monitor what is happening in real time. And the applications object database allows Montero to easily replicate processes from one plant to the next. A global deployment affords the company the flexibility to quickly create, change, and replicate KPIs related to process improvements. The main purpose of this system is to have information in real time so that the plant people can be more productive and can deal with any day-to-day problems, Montero says. However, the company has quickly realized the value of this system. It is not just improving efficiency; we need this communication, he says. We have come to depend on this.

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DB Breweries Reduces Complexity and Improves Efficiency

Wonderware user-friendly software solutions enable brewery to gather far-flung data to pinpoint problems and act quickly to address them.

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obody wants to waste a drop of good beer, whether youre drinking it or making it. At DB Breweries, a New Zealand-based brewery, finding a way to capture the 2% to 3% of the bottom beer that leaks from a tank during the brewing process means saving money from going down the drain literally. When company engineers began looking at ways to improve utilization, they used proactive monitoring technology from Wonderware to identify the root cause of the waste. The problem: a leaky valve. The solution: a new centrifuge to extract the beer and pull it back into the process. This was hardly a make-or-break situation for the maker of the legendary Tui beer and other brands, including Heineken, Monteiths, Export Gold, Amstel, and DB Draught. But for a company with four breweries and an emphasis on double-digit annual

growth, every drop counts. The key is that we can make changes rapidly, says Stephen Vidulich, DB Breweries business systems manager. The leaky valve example is just one of many ways that the companys Brewing Process Improvement Team, a group that blends IT and production expertise, is taking action. Other areas of concentration include automating data collection, tracking batches, building a common reporting system, and loosely coupling ERP and plant floor systems. DB Breweries faces the same problem that manufacturers in every industry struggle with: how to extract data and, more important, act on it. The brewery, which was acquired by Asia Pacific Breweries in 2004, must also be able to share best practices company-wide and find effective ways for everyone plant managers, engineers, IT, and executives to access the right information

when needed and have it delivered in the right context. To accomplish those goals, the company formulated a vision that would leverage technology to gain efficiency throughout the business. And the first thing executives decided to do was to standardize on its SAP ERP system. For its operations management software, the company chose Wonderware technology, including the Wonderware Historian software to gather historical data, InTrack software to trace batches, and the InTouch HMI operating interface. The vision came about because we wanted to get information that we knew was rich at the plant floor, but the IT people didnt know how to get to it, Vidulich says. The Wonderware-SAP solution is solving the problem, allowing DB Breweries to execute on its strategic plan of sharing data across the organization, even if it resides in hard-to-reach places in the plant.

Pouring over the Mix

As with any business strategy, the company needed first to put a solid plan in place. In order to understand the needs of each department, Vidulich and his team began to define how information needed to be delivered. In any organization, there is so much complexity, he says. One of the key things that can break down that complexity is simplicity. Break it down into simple modules. To do that, Vidulich outlined what the team needed to achieve and how far they could push the boundaries of technology. We put the vision together void of an actual solution. But we asked the question, What do we want to achieve in an ideal world? What they realized was that the technology they chose, like their project strategy, had to reflect a big-picture vision supported by simplicity. Wonderware technology, such as InTouch HMI, with which Vidulich was familiar, is simple, but powerful, he says. That rang true to me. Simplicity must be inherent in the technology and applications that the company uses to achieve operational efficiency; otherwise people wont understand them and wont use them. Vidulich learned that lesson firsthand with early Unix-based systems, which required high-level expertise to maintain. The Microsoft-based Wonderware applications, on the other hand, dont have a complex scripting engine, but rather an easy-to-understand modular approach that enables anyone on the plant floor to find information, he says. DB Breweries is using Wonderware technology at three breweries, and it is already proving to be a valuable asset. The company

rolled out the Wonderware Historian software first, as a way to understand inefficiencies in the plants energy consumption, including carbon emissions and water waste. The team hooked up 7,500 tags to digital valves to measure flows, pressure, and temperature, and tasked engineers with evaluating the energy efficiency of specific pieces. Within the first month, they found huge inefficiencies in water usage in pumps. By identifying that issue, we saved $20,000 to $30,000 within the first few weeks, Vidulich says. As a result, engineers at DB Breweries applied the Wonderware technology more broadly, tagging 20,000 data points and, again, realizing immediate savings in water usage and CO2 emissions. As part of the solution, there are automatic triggers that notify key users by text and e-mail when a strategic plant is down or limits are reached. In addition, the company tied the SAP plant maintenance application together with Wonderware Historian software. If a particular item goes over a certain pressure for a specific amount of time, for example, Wonderware Historian software will text the engineer to say there is a problem, Vidulich says. The key is that the Wonderware software solutions deliver information in a way that enables people to act decisively. It does this by interoperating with a variety of existing applications and control technologies in the plant, such as SAP software or PLCs from third-party vendors. Information needs to travel at the speed of light. Whether its good or bad, it needs to get to the right people at the right time or its meaningless, Vidulich says. Wonderware technology, he says, has enabled DB Breweries to move forward with its vision to use technology to gain efficiencies. Now, Vidulich wonders how the company operated without the technology. We are using it all the time. Wed be lost without it, he says. And so would all that bottom beer. 7

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