IN12 - Increase Operations Efficiency and Profitability Using Configurable Workflows

IN13 - Increase Operational Flexibility with Data-Driven Decisions for Easier Compliance

IN14 - Better Manage OEE for More Efficient and Profitable Operations

For Classroom Use Only!

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Information Software

Contents
Lab Introduction ............................................................................................................................................ 5
Audience and Expectations .............................................................................................................................................................. 5
About this Lab ................................................................................................................................................................................... 5
General Terminology ........................................................................................................................................................................ 6
Prerequisites ..................................................................................................................................................................................... 7

Scenario Overview Lab ................................................................................................................................. 8

Accessing the Home Page............................................................................................................................................................... 8

FactoryTalk Production Lab ........................................................................................................................ 10

Objective ......................................................................................................................................................................................... 10
Terminology .................................................................................................................................................................................... 10
View Bill of Materials ....................................................................................................................................................................... 11
Configure a User Workflow ............................................................................................................................................................. 13
Panel Widget................................................................................................................................................................................... 18
Create Build Plan ............................................................................................................................................................................ 20
Production Execution Client ............................................................................................................................................................ 25
Reports ......................................................................................................................................................................................... 27

FactoryTalk Performance Lab ..................................................................................................................... 29

Objective ......................................................................................................................................................................................... 29
Terminology .................................................................................................................................................................................... 29
Login to the FactoryTalk Performance Web Interface .................................................................................................................... 30
View the Plant Model Editor ............................................................................................................................................................ 32
View the Tag List Editor .................................................................................................................................................................. 33
View the Materials Editor ................................................................................................................................................................ 33
View the Work Schedule Editor ...................................................................................................................................................... 34
View the Station Editor.................................................................................................................................................................... 34
View the Bill of Materials Editor ...................................................................................................................................................... 35
View the Panel Widget Editor ......................................................................................................................................................... 35

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View the Editor Configuration Settings Editor ................................................................................................................................. 36
View the Line Configuration Editor.................................................................................................................................................. 37
Duplicate the Line Configuration ..................................................................................................................................................... 37
View Data Collection Editor ............................................................................................................................................................ 41
View Units of Measure Editor.......................................................................................................................................................... 46
View Reason Codes Editor ............................................................................................................................................................. 46
View Loss Category Editor.............................................................................................................................................................. 47
Verify Setup .................................................................................................................................................................................... 47
Backup ............................................................................................................................................................................................ 48
Production Execution Client ............................................................................................................................................................ 49
Perfromance Dashboards ............................................................................................................................................................... 54
Site Level Dashboards .................................................................................................................................................................... 55
Area Level Dashboards .................................................................................................................................................................. 58
Machine Level Dashboards ............................................................................................................................................................ 59
Reports ........................................................................................................................................................................................... 59

FactoryTalk Quality Lab .............................................................................................................................. 62

Objective ......................................................................................................................................................................................... 62
Terminology .................................................................................................................................................................................... 62
Login to FactoryTalk Quality Web Interface .................................................................................................................................... 63
Review the Existing Configuration .................................................................................................................................................. 64
Create Quality Recipe ..................................................................................................................................................................... 70
Panel Widget................................................................................................................................................................................... 81
Activate Quality Recipe ................................................................................................................................................................... 81
Configure Notifications .................................................................................................................................................................... 81
Reports ........................................................................................................................................................................................... 84

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Lab Introduction

Audience and Expectations

This guide is intended for experienced professionals who understand their company’s business needs as well as the technical
terms and software dependencies described in this guide. This manual covers the configuration and running of our Fit For
Purpose applications: Production, Performance, and Quality using a FactoryTalk® ProductionCentre (FTPC) framework.
Supporting software such as FTPC and Fit For Purpose applications and related databases, have been pre-installed. This
document does not provide installation instructions for related components, like database software or internet connections.

About this Lab

This lab includes an overview of our Fit For Purpose applications:
• FactoryTalk Production
• FactoryTalk Performance
• FactoryTalk Quality
After the instructor overview, students may select the lab application exercise of their choice, make modifications to the existing
demonstration applications or create additional configurations. Please take the opportunity to explore the pre-configured
application. There is one lab for each of the Fit For Purpose applications. Each lab duration will vary from 30-60 minutes each.

FactoryTalk Production is an application used to create a discrete application that allows Unit, Lot, Part, Box, and Carrier
based transactions. It provides out-of-box functionality to create and track multiple Units, Lots, Parts, Boxes, and Carriers. It also
provides functionality to perform consumption, monitor equipment, and generate reports. Using the Production application, a
discrete application can be created by configuring objects that have pre-defined functionality.
Some examples of how the Production application can be used:

Creating and tracking Units, Lots, Boxes, Carriers, Work Orders, and Work Order Items

Collecting data

Performing consumption

Viewing Work Instructions

Creating a discrete Production application Build Plan

Creating User Workflows

Adding Widgets to User Workflows and configuring Widgets

Creating and editing Panel Widgets

FactoryTalk Performance is a plant-level application that monitors process and packaging line efficiency, captures downtime
events, and provides an approach to comprehensive root cause analysis. The Performance application enables users to set
performance goals, such as yield, quality, schedule adherence and overall equipment effectiveness. This application also allows
you to track progress in real time against those goals.
Some examples of how the Performance application can be used:

Monitoring the plant floor

Defining a Plant Model that defines the layout and configuration of the Production Line for which you want to collect data

Defining multiple configurations for a single Production Line

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Defining the tags that will be monitored for state change events as well as production counts, job tracking, and flex fields

Creating loss categories, reason codes, measurement units, and measurement unit groups

Configuring data collection

Configuring administrative tasks such as creating Users and User Groups, monitoring and controlling the Data Collection
and ETL services, and starting Purge

Executing Jobs

Editing, splitting, and merging Events

FactoryTalk Quality is an application that allows you to run quality policy checks for your factory. If your production must follow
certain regulations, the Quality application can be used to verify that the regulations are met.
Some examples of how the Quality application can be used:

Checking that the proper temperature was used at a work station or a piece of equipment

Providing correct color picture to compare the product color and decide whether the product was produced properly

Using Escalation Plans when the values entered for the Standard Plan fall outside of the acceptable range or if the item
fails the Recipe Item check

Sending notifications when a Sample Plan is created, completed, failed, or expired

General Terminology
The following terminology is used throughout the lab manual and is included to help introduce terms and grammar used within
the Fit for Purpose applications.

Setup editors: The Setup editors allow you to configure the objects for your application. When Fit For Purpose
applications are installed, the Setup editors will appear beneath the list of application-specific editors on the editor
list.

Plant Model: A hierarchy of FactoryTalk ProductionCentre (FTPC) resource objects that models the physical
plant floor manufacturing environment. Use this editor to define the layout and configuration of the production
lines for which you want to collect data. For each production line, create a layout that describes how the machines
within that line operate when producing a specific material or overall when a material is not defined.

Tag Lists: Use the Tag List Editor to define a list of tags, which can be used for purposes such as monitoring for
data change events. Changes to these tags determine the state of the machine associated with it. You can also
use this editor to create filters for the tag list.

Part: A Part object is the product to be produced on a production line.

Work Instruction: A work instruction can be displayed to an operator and provide an interface in which data can be
entered. Work instructions support the following file formats: .doc, .txt, .pdf, .xls, .xlsx, .jpg, and .gif. Files of format
.xml are not supported.

Work Schedule: Use the Work Schedule Editor to add or edit work schedules.

Stations: The Station editor consists of a table that lists the names, descriptions, and number of assigned
resources for each Station. Use this editor to associate stations to Production Lines. Each Station can be
associated with multiple Production Lines.

Data Collection: Use this editor to define the attributes for which you want to collect data.

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Materials: Use this editor to view, create, edit, and delete materials produced on a Production Line.

Production Execution Client (PEC): The Production Execution Client (PEC) is a graphical user interface (GUI) that
allows you to run the User Workflows and Panel Widgets created through the Setup interface editors. The
capabilities of the PEC may be expanded via additional customizations and modules installed on top of
FactoryTalk Production. For example, with the FactoryTalk Production module installed, FactoryTalk Production
Build Plans and their associated workflows will appear on the client in addition to base FactoryTalk Production
workflows and panel widgets.

Prerequisites
This lab includes the demonstration applications that were shown in the instructor overview. The following objects have been
created for the demonstration and are available to explore.

All the objects required for the Plant Model (Production Lines, Work Centers, etc.)

Parts (i.e., what is consumed and what is produced)

Bill of Materials (list of specific sub-components required to build a part)

Optional objects that will be used (for example, Work Instructions, DCS, Work Schedules)

User Workflows and Panel Widgets

Build Plan that associates the Parts to the Production Line where the 15 Inch View Panel will be manufactured

Quality Recipe and Quality Recipe Items configured for 15 Inch View Panel to verify the manufacturing regulations are
met
Follow the exercise scenarios below to become familiar with how easily you can learn and navigate the applications.

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Scenario Overview Lab

In this lab, you will be able to view the Fit For Purpose applications. From the home page, you can access any of these
applications to view the configuration or you may access the Production Execution Client (PEC) to run the Panel Widgets or User
Workflows created through the configurations. The Production and Performance Reports may be accessed from the home page
Reports link and the Quality Reports may be accessed from a URL to the SSRS Reports. Other octagons on the home page
include Administration, About, and the Warning and Error Log.
Our sample scenario is producing a 15 Inch View Panel on an assembly line. Explore the entire Plant Model with its related
Production Line, Units of Measure (UOM), Work Schedule, and Resources.
In the Production application, view the objects that are required to produce a 15 Inch View Panel on an assembly line. In each of
the editors, you will see what objects were configured to manufacture the 15 Inch View Panel.
In the Performance application, view the plant-level application required to monitor the manufacturing process of a 15 Inch View
Panel. You will see the configurations used to determine the performance rating of each piece of equipment, the percentage of
good parts that are produced, and other performance goals set such as yield, quality, schedule adherence and overall equipment
effectiveness (OEE).
In the Quality application, view the Quality Recipe that is required to run quality policy checks when producing 15 Inch View
Panels. You will see which objects are needed to verify that the regulations are met. An operator can make a decision as to
whether or not the 15 Inch View Panel was produced properly.
The student image includes the same configurations as the demonstration. Explore the 15 Inch View Panel configurations. The
lab manual provides you with high-level steps to explore each application and guides you to add a new product, a 20 Inch View
Panel. It is not required that you follow the exercise steps explicitly.

Accessing the Home Page

To access the desired Fit For Purpose application, launch the home page by performing the following steps.

1. From the desktop, double-click the shortcut icon, or manually navigate to http://localhost:8080/FTPCApps from
your Internet Explorer browser.

2. Access the desired Fit For Purpose application by clicking on the octagon. Enter the login credentials for User Name as
‘admin’ and Password as ‘admin’.

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The following sections provide steps to guide you through your journey with the Fit For Purpose applications.

THIS LAB IS COMPLETE.

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FactoryTalk Production Lab

Objective
To keep pace with ever changing consumer demand requires flexibility in your manufacturing processes and systems. This
exercise demonstrates how operations personnel can easily create a new Build Plan and adjust workflows to manufacture a new
product.
In your student image, the applications are configured with the existing Build Plan for manufacturing a 15 Inch View Panel; yet
consumers are demanding a 20 Inch View Panel. In your exercise scenario, a new 20 Inch View Panel Build Plan will be created
on the existing Production Line.
In this section, you will learn how to:
• View Bill of Materials (BOM)
• Configure User Workflows
• Configure Panel Widgets
• Create a Build Plan
• Execute a PEC
• View Reports

Terminology

Object Supervisor Panel Widget: The Object Supervisor Panel Widget is provided for Units, Lots, Boxes, and
Carriers. The Supervisor Panel Widget provides an interface that allows you to perform transactions on these
objects outside the route enforcement restrictions of the User Workflow as well as view a Work Instruction and
print a label.

Order Management Panel Widget: The Order Management Panel Widget provides an interface that allows you to
perform transactions on a Work Order, view a Work Instruction, and print a label.

Track and Trace: Determines where the object has been and it’s current location.

Scan and Start: A tracked object is placed on the User Workflow and started when the required information is
scanned. This option is only available when the Track and Trace task type is selected.

Select and Start: A tracked object is placed on the User Workflow and started when the required information is
selected. This option is only available when the Track and Trace task type is selected.

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View Bill of Materials
The Bill of Materials (BOM) is a list of specific sub-components required to build a part. BOM objects allow you to create a list of
required materials linked to the parent and child Part. The BOM is associated to BOM Items which are associated to Parts.

1. Select the “FTPC Apps” icon from the desktop and double click it to launch the FTPC Apps
landing page.

2. To view the configured BOM, select the icon “Production Management”.

.
3. Enter the User name “admin” and password “admin”.
4. From the navigation pane, select the button “Bill of Materials”.
5. Select the 20 Inch Panel.

The Bill of Materials for the 20 Inch View Panel is already configured.

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We will now configure the user workflow. When the Build Plan is being configured, a User Workflow is attached to each
Equipment resource in the Production Line. A User Workflow determines which tasks, if any, an operator must perform at
each resource. The Production application provides a series of Widgets that can be added to each User Workflow. These
Widgets provide the functionality for tasks that can be performed at a particular route step (for example, scan and start lots,
consume units, and data collection). Each User Workflow can be assigned to multiple Work Centers/Equipment.

6. Configure the Part to the BOM by selecting Part from the navigation and then the “20 Inch View
Panel”. Select the Edit button to associate the part to the BOM.

7. Select the ellipse button next to the Bill of Material field and chose the correct BOM (20 Inch
Panel). Click OK and Save to complete.

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Configure a User Workflow
A user workflow describes the tasks that take place at work centers and equipment in the discrete build plan. These tasks are
defined by adding widgets to the workflow. Widgets define specific functionality that needs to be performed at a resource. User
workflows can be run from the production execution client (PEC).
1. From the navigation pane, select “User Workflow”.

2. Select the ‘20 Inch Panel – Board Assembly’ User Workflow.

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3. Select View.
4. In order to add a Work Instruction and Consumption Widget, click the Edit button. A list of
available Widgets can now be seen. Widgets define specific functionality that need to be
performed at a resource level. Widgets can be easily dragged and dropped into the User
Workflow.

5. Drag the Instruction widget under the “Unit Select Start” widget in the work order list view.

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6. Select the Unit Select Start Widget and then the Configuration button. Set the panel refresh info
as ‘Refresh Visible’.

7. The next step is to configure the Instruction Widget. Select the Instruction Widget and then select
Configuration.
8. We’re going to add a work instruction to the Widget; this work instruction (WI) is in the form on an
image file which provides useful instruction to the Operator when assembling the 20 Inch View
Panel. Select the ellipse button to add a new Work Instruction. Select the “Chassis WI” work
instruction and click OK and Save to complete.

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9. Drag and drop the “Unit Consume” Widget under the Instruction Widget.
10. For the Unit Consume Widget Configuration, we will now browse and select desired BOM items
to be consumed. From the configuration window for the Unit Consume Widget, select the ellipse
button under Consumption Information and then select the “Logic Board” BOM item for the “20
Inch View Panel”. Click OK and Save to complete.

11. The Workflow should now be configured. Select Save at the bottom of the screen.

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Panel Widget
Panel widgets are customizable widgets that provide a graphical user interface (GUI) and
can be run from the PEC.

1. Select Panel Widget from the navigation pane.

2. Click Add.

3. Name your Panel Widget ‘Supervisor Panel’. Select type as “Unit Supervisor Panel”. Define the
caption as “Supervisor Panel” and Category as “Supervisor” . The caption will be displayed on the
Startable panel of PEC.

4. Click Save and Close to complete.

5. Now we will assign this new Panel Widget to a Supervisor Station

6. First create a Station for the supervisor by selecting “Station” from the navigation pane.

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7. Click Add to create the new station. Name it “Supervisor Station”.

8. Save and close the dialog.

9. From the navigation pane select “Panel Widget”.

10. Select the “Supervisor Panel”

11. Click Assign > Assign Stations. Select “Supervisor Station”.

12. Select save to close the dialog.

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Create Build Plan
Build plans determine which part or set of parts can be produced on a particular production line as well as the steps required to
produce the part(s) on a production line. Once your user workflows and widgets have been defined, create the build plans that
will determine where the workflow tasks will be performed.
We will now create a Build Plan. The Production application’s Build Plan associates the Part being manufactured with the
Production Line and the steps required to produce the Part on each piece of Equipment.
1. Select the Build Plan button from the navigation bar.
2. We will now create a Build Plan to produce a 20 Inch View Panel. Click the Create button.

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3. Name your Build Plan ‘20 Inch View Panel’ with the same description.
a. Define the version: 1
b. Select Part: 20 Inch View Panel
c. Lot Name Generator: 20 Inch Lot Name
d. Unit Name Generator: 20 Inch Unit Serial
e. Production Line: View Panel Assembly Line. Click + to add to the list.
View of completed build plan.

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4. Ensure that the route enforcement is set to ‘Start and Complete’. This will enable route
enforcement for both start and complete transactions. Select this option to enforce route
enforcement when a tracked object is either started or completed at a route step. This is the
default.
5. Select Next to continue.
6. Click the the “View Panel A…” box. And select the “Allocated” check box. Click OK to close the
dialog.

7. Click Next to continue through the wizard.

8. Select OP060 and Check the Allocated Box and assign the User Workflow “20 Inch Panel - Board
Assembly” then click OK to close the configuration dialog.

9. Repeat the same steps to allocate the “20 Inch Panel - Screen Assembly” Workflow to OP070.
10. Select Next and then Finish to complete the configuration.

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11. Select the “20 Inch View Panel” Build Plan and then View to see the Build Plan editor.
12. To view the machines with allocated User Workflows, select the “View Panel Assembly Line
Workcenter” box and then the View Equipment button.

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 When a Build Plan is created, a route is also created from the Plant Model associated with the
Build Plan. Any connection that was defined as the main path in the Plant Model editor will
automatically be defined in the route as the main path with the Reason Code ‘OK’. To move a
selected object, select the green box that appears in the upper left corner of the selected object
and drag the object to the desired location. If a route step has only one outgoing route arc, the
Reason Code defaults to ‘OK’. The route created for this Build Plan may be viewed.
13. Validate your Build Plan to ensure that the Build Plan has no errors.

14. Select the Approve and Activate buttons for your Build Plan so that you may create a Work Order
and process Units. The effectivity start should be set for today’s date so that you can use it to
process a Work Order.

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Production Execution Client
The production execution client (PEC) is a graphical user interface (GUI) that allows you to run the
user workflows and panel widgets created through the Setup interface editors. The capabilities of the
PEC may be expanded via additional customizations and modules installed on top of Production
Management. For example, with the Production Management module installed, Production
Management build plans and their associated workflows will appear on the client in addition to base
Production Management workflows and panel widgets.

1. Click on Home in the browser and then access the Production Execution Client.

2. Change to the station by selecting the current station from the menu:

3. Select the 20 Inch View Panel Assembly 1 Station. The Panel Widget Order Management is
already configured and assigned to a Station.
4. Select the Order Management Panel Widget from Startable panel.

5. Create a Work Order by defining the required attributes.

6. Confirm the Work Order.

7. Select Work order Dispatch for the 20 Inch View Panel Build Plan.

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 The Work Order will be dispatched using the selected Build Plan with the selected Production
Line. When the Work Order is dispatched, the new Lot or Units will be created and placed on the
entry queue of the route.
8. Select the Build Plan and Production Line and then click Confirm to continue.
Note: The Dispatch of the Work Order may take a few minutes to complete. If the work order
does not complete dispatching, go to the next step. If the Build Plan is present you can continue.

9. Select the Build Plan from the Startable panel.

10. Select a Unit for the Unit Select Start Widget.

11. Read the Work Instructions for the Instruction Widget.

12. Define the unique Part name to be consumed for the Unit Consume Widget.

13. Select Reason ‘OK’ from the drop down list for the Unit Complete Widget.

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 Reports
1. In this section, we will view the Production application Reports.
2. Click the Reports octagon from the home page.

3. Select ‘Production Management’ from the drop down list.

4. Select the desired Report, define the filter values, and view any of the available reports. The
report data has units within the following range: RAPANEL-00001 through RAPANEL-00015.
The date range of the data starts from March 27 – April 10, 2017.
5. Some of the Production application Reports are defined below, please take the opportunity to
explore the other reports.

Genealogy Report
The Genealogy Report (Genealogy_ V3) shows the tracked, consumption, and data collection history for the selected Unit
or Lot. The report displays all the transactions performed on the selected object and what was consumed into it.
Hint: To run the report type ‘RAPANEL-00001’ in the Lot/Unit field and then select the View
Report button.

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Production Report
The Production Report (Production_V3) shows the current Lots or Units that have been finished, shipped, and closed per
Production Line per resource. If the type selected is Lot, then an extra column displaying the Lot Quantity is displayed.
Hint: There may not be any recent data for this report, but you can select This Year to see
data for this report

Production Summary Report

The Production Summary Report (ProductionSummary_V3) shows the current count of Lots or Units that have been finished,
shipped, and closed.
Hint: There may not be any recent data for this report, but you can select This Year to see
data for this report

THIS LAB IS COMPLETE.

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FactoryTalk Performance Lab

Objective
To keep pace with ever changing consumer demand requires flexibility in your manufacturing processes and systems. This
exercise demonstrates how operations personnel can easily add a new product and configure the line with the appropriate Line
Rates and Bottlenecks in order to analyze performance data.
In this exercise, you will need to configure Line Management that monitors process and packaging line efficiency, captures
downtime events, and provides an approach to comprehensive root cause analysis. You will need to set performance goals,
such as yield, quality, schedule adherence and overall equipment effectiveness, and track progress in real time against those
goals.
In this section, you will learn how to:
• Create a Line Configuration
• Add a Panel Widget to configure an Operator View
• Run the Production Execution Client (PEC) to view updates
• Edit an event in PEC
• View Reports
• View Dashboards

Terminology

Production Line Counts: Total (input) counts for a production line are computed from the sum of all machines
marked with the Total role. Good (output) counts for a Production Line are computed from the sum of all
machines marked with the Good role. Production Line counts are computed whenever the machines with Total or
Good roles have their counts collected.

Overall Equipment Effectiveness (OEE): Determines the performance rating of manufacturing equipment. The
OEE is used to determine if a machine or Production Line is performing adequately. This information allows you
to assess a single machine’s performance over time or to compare the performance of machines to each other.

Availability: A ratio of production time to scheduled time.

Performance: The performance of a machine is the ratio of available time to scheduled time.

Quality: The percentage of good parts that are produced.

Mean Time Between Failure (MTBF): The average amount of time that a piece of equipment was in a running
state between failures.

Mean Time to Repair (MTTR): The average amount of time that a piece of equipment was in a failure state.

Downtime: The total of scheduled and unscheduled downtime activities. How downtime is categorized is not
important to the actual calculation of OEE, but OEE is typically analyzed according to how these losses are
categorized.

Unscheduled Downtime: Unplanned stoppages during production. For the purposes of OEE, unscheduled
downtime should be classified as breakdowns/machine failures (requires maintenance) and setup and
adjustments.

Scheduled Downtime: Lost time activities or events when the Production Line is not occupied to produce.

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Scheduled Time: Total hours the Production Line is occupied with some type of activity (i.e., Production or
Downtime) or is not physically capable of production. In general, this would correspond to a shift or other time
period.

Total Time: The gross available hours for what time base is being considered (i.e., eight hours per shift, 24 hours
per day, etc.).

Available Time: The production time minus unscheduled down time.

Productive Time: The available time minus the standby time, which is any non-producing time during available
time, such as when equipment is waiting for materials, test results, etc.

Unit of Measure: Use this editor to create units of measure for the material produced at each Production Line.
Each unit of measure has a conversion factor relative to a base unit of measure, which enables values to be
converted between any unit of measure within the measurement unit group.

Loss Categories: Use this editor to create Loss Categories that can be used to categorize events that affect OEE.
These categories apply to all Production Lines and their machines, which enables performance analysis between
lines.

Reason Codes: Use this editor to create Reason Codes that will map to state change events. The Performance
application requires a Reason Code for each of the default states in order to compute OEE.

Login to the FactoryTalk Performance Web Interface

1. Click the Performance Management icon:

2. Enter username admin and password admin (all lower case) and click Login:

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3. Observe that the FactoryTalk Performance Web Interface consists of two grouped sets of editor buttons:

Note: The first set of buttons are FactoryTalk Performance specific, while the second set of buttons
are common to all three applications (i.e., also applicable to FactoryTalk Production and FactoryTalk
Quality). We will start by examining the common buttons.

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View the Plant Model Editor

4. Click Plant Model:

5. Observe the complete Plant Model by fully expanding the Twinsburg Operations Site tree to the
Equipment level:

Note: The equipment is contained in the Work Center ’View Panel Assemble Line WorkCenter’.

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View the Tag List Editor

6. Click Tag List to view a list of tags to be monitored for data change events:

View the Materials Editor

7. Click Materials to display a list of existing Materials:

Note: There are materials for both 15 Inch View Panels and 20 Inch View Panels.

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View the Work Schedule Editor

8. Click Work Schedule to display a list of work schedules:

9. From the Work Schedules list box select 2017 WorkSchedule and observe the 3 shifts (A,B & C):

View the Station Editor

10. Click Station to see a list of stations and their associated production lines:

Note: There are stations for both 15 Inch View Panels and 20 Inch View Panels.

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View the Bill of Materials Editor

11. Click Bill of Materials:

12. A Material object is the product to be produced on a production line:

Note: They exist for both 15 Inch View Panels and 20 Inch View Panels.

View the Panel Widget Editor

13. Click Panel Widget to view the customizable Widgets that provide a graphical user interface
(GUI) and can be run from the Production Execution Client (PEC).

14. The following 6 FactoryTalk Performance Panel Widgets are pre-configured and pre-assigned to a
Station for this exercise:

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View the Editor Configuration Settings Editor
15. Click Settings and then Change Configuration to view the Editor Configuration:

16. Click Cancel (no changes are required).

Note: This concludes the application common buttons. In the following sections, we’ll examine the
buttons applicable only to FactoryTalk Performance.

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View the Line Configuration Editor
17. Click Line Configuration:

18. From the Line list box select View Panel Assembly Line as shown below:

19. Observe that the only Line Configuration currently available is ‘15InchPanel’:

Note: We need to create the Line Configuration for the 20InchPanel by duplicating the
15InchPanel and making modifications.

Duplicate the Line Configuration

20. Slowly move the mouse over the 4 Line Configuration buttons until you locate the Duplicate selected Line
Configuration button:

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21. Click the button and the Duplicate Line Configuration dialog should appear populated with existing
15InchPanel Line Configuration:

22. In the Line Configuration editor box, rename this line as ‘20InchPanel’:

Note: The existing Line Configuration 15InchViewPanel will produce 2 units/minute using
two parallel machines (OP020A & OP020B). The new 20 Inch View Panels will be produced
at a rate of only 1 units/minute (we will only need machine OP20A). We also want the new
20 InchPanel to be the Default Configuration.

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23. Make the required changes for the 20InchPanel changes as shown below:

Note: Changes are required for the following columns: Monitor, Ideal Run Rate, Total
UOM, and Line Bottleneck. Make sure to check the Default Configuration checkbox.

24. Click Save. Observe that the Line Configuration is now ‘20InchPanel’, but Default UOM is still 15
Inch Screen:

Note: Both the Default UOM and the Line Configuration need to be 20.

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25. Click Edit and change the default Unit of Measure (UOM) from ‘15 Inch Screen’ to ’20 Inch Screen’ as
shown below:

26. Click OK and then click Save. Verify the new default UOM = ‘20 Inch Screen’:

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View Data Collection Editor

27. Click Data Collection:

28. From the Line list box select View Panel Assembly Line and observe the 5 input tags from the controller:

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29. Click the Data Output and observe the 13 optional output tags to the controller:

30. From the Work Center list box select View Panel Assembly Line WorkCenter and observe the absence
of any tags:

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31. From the Equipment list box select OP010. This is Data Collection Configuration overview:

32. Select Count/Job to observe the Job tags (ID, Material & Quantitiy) and the Count tags (Total, Good &
Reject):

33. Click the Event icon and observe the single Event tag. This tag is used to define the state of the machine.
Note that a machine can only be in one state and any time.

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44 of 88
34. Click the Data Output dialog and observe the Count tags (Total, Good & Reject), Key Process Indicator
tags (OEE, Availability, Performance, Quality, MBTF & MTTR):

35. Click Flex Fields and observe the 10 available Flex Fields. Flex Fields are used to capture additional data
at the time of a state change; they can be used when developing custom reports.:

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View Units of Measure Editor

36. Click Units of Measure:

37. Observe the dialog and the associated parameters:

View Reason Codes Editor

38. Click Reason Codes:

39. Observe the existing Reason Code groups (Machine Faults, Running, Stopped, Not Scheduled) and their
associated configurations:

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View Loss Category Editor

40. Click Loss Category:

41. Observe the 5 Loss Categories and their associated Codes and Subcategories:

Verify Setup

42. Click Verify Setup:

43. From the Line list box, select View Panel Assembly Line and Verify Tags and then click Verify:

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 44. The validation should complete with 0 error(s):

Backup

45. Click Backup:

46. Click Export and accept the default file name and initiate the backup (this will take several minutes and the
status bar may stop and flash for part of the export process):

47. Select Cancel when prompted after the download completes.

48. Select Save As and choose the desktop as the destination. Minimize Internet Explorer and open the file in
Excel. Observe the individual sheets for the configuration properties and objects in each editor. The column
names are based on the properties that are defined when creating each object. For example, when creating
a material, you enter the material name and description. Therefore, the spreadsheet will have columns for
name and description.

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Production Execution Client
49. Change Applications to the Production Execution Client (PEC):

50. Observe the Production Execution interface (also known as the “Cockpit”) with the Startable
Panel (containing widgets) and the Running Panel (currently empty):

51. Verity that the Station = ‘Station Performance’ (as opposed to ‘Qualtiy’). If not, change it to
Station Perfromance.

52. Click the Startable Performance Data Collection Control widget:

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53. To apply changes made to the Performance Configuration, the Data Collection services requires
a restart. Click the Restart button and then OK to confirm:

54. Return to the Cockpit by clicking the Cockpit button.

55. Click the Startable Panel View Operator Console widget:

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56. Observe the existing View Panel AssemblyLine for 15 Inch Panels:

57. Select the Job 15 Inch Panel and click Complete:

58. Click the Jobs Add button and create a new job called ‘20 Inch View Panel’ by selecting the
‘20InchPanel’ line configuration and defining the rest of the attributes as shown below:

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59. Select the Job 20 Inch Panel and click Start:

60. Start the job and observe the Summary View screen. Note: The machine states are changed. If a
machine is in a Producing state, it will display in green color.

61. Return to the Cockpit and click the Startable Performance Events widget:

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62. View the Events by selecting the ‘All Events’ filter:

63. Select an Event and click Edit:

64. Enter a New Reason and click Save.

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 65. Return to the Cockpit.
66. [Optional] Use the PEC to view and explore the remaining Panel Widgets.

Perfromance Dashboards
67. Return to the Home page and click Performance Dashboard:

68. Observe the Dashboard user tasks supported (bulleted items):

69. Expand Views to the Twinsburg Operations Site level as shown below:

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Site Level Dashboards
70. Site Monitor dashboards show the progress through the current job for each Production Line at a
site. Select the Site Monitor dashboard as shown below:

Performance Analysis dashboards are updated every five minutes. If the new order was just started, the
Site Monitor may still say “15 Inch Panel” or “Not running an order”. If so, you may need to wait several
minutes for the 20 Inch View Panel Order to start running. If you wish to proceed with the lab steps, you
can view the drill thorugh for the following step even if it is not showing “20 Inch View Panel”

71. In the right hand pane, click the 20 Inch View Panel Assembly Line:

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72. The View Panel Assemble Line Monitor should appear:

73. Select the Site Performance Review dashboard (which defaults to Productivity > OEE):

74. To specify dates, download the report or refresh the report, use the icons in the upper right
corner. Select “This Month”

Performance Analysis dashboards are updated every five minutes so there may not be data in the reports yet. If there
is no current data, selecting ‘This Year’ should show data that was collected earlier in 2017.

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75. Also select the other available Productivity dashboards:

76. Select the Losses dashboard (which defaults to Losses > All Losses):

77. Also select the other available Losses dashboards:

78. Select the Failures dashboard (which defualts to Failures > MTBF):

79. Also select the other available Failures dashboards:

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 80. Expand Views to the Operator Interface Area as shown below:

Area Level Dashboards

81. Area Monitor dashboards show the progress through the current job for each Production Line in a
given area. Click the Area Monitor and Area Performance Review reports.

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Machine Level Dashboards
82. To view all the available Performance Dashboard reports down to the Machine level, right click on
the Views and Expand All:

Reports
83. Return to the Home Page and click Reports:

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 84. From the drop down list, Select ‘Performance Management’ and click View Report:

85. Select the desired Report, define the filter values, and view any of the available reports. The
report data has units within the following range: RAPANEL-00001 through RAPANEL-00015.
The date range of the data starts from March 27 – April 10, 2017. Some of the Performance
application Reports are defined below:

Availability Loss Report

The Availability Loss Report (AvailabilityLoss_v3) shows a breakdown of the OEE component availability as both
a chart and a table. A Production Line’s state is based on the Bottleneck machines only. Therefore, availability
calculations are based on the states of the Bottleneck machines.
The Report is displayed in the following image:

Breakdown Losses Report

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 The Breakdown Losses Report (BreakdownLoss_v3) shows the distribution of breakdowns by machine for a
given line as both a chart and a table. A breakdown is registered when a machine changes to the Unscheduled
Downtime state. The following information is displayed in the following image:

Time: The amount of time, in minutes, the line experienced a breakdown.

Count: The number of breakdowns on this line during the given start and end dates.

Dashboard Report
The Dashboard Report (Dashboard_v3) shows an overall, summarized review of the selected line or machine over
the specified time range. The following information is displayed in the following image:

OEE: The overall OEE value, as a percentage, as a result of Availability x Performance x Quality

Availability: The availability percentage.

Performance: The performance percentage.

Quality: The quality percentage.

Total Parts: The total number of parts (both good and rejected) produced.

THIS LAB IS COMPLETE.

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FactoryTalk Quality Lab

Objective
To keep pace with ever changing consumer demand requires flexibility in your manufacturing processes and systems. This
exercise will demonstrate how quality personnel can easily create a new Quality Recipe.
In this lab, you will create quality checks for a 20 Inch View Panel manufacturing unit. This will give you an opportunity to see the
interaction between the Plant Model, Quality Recipes, Quality Recipe Items, Standard Recipe Plans, and Escalation Plans.
In this section, you will learn how to:
• Create Quality Recipe
• Create Quality Recipe Items
• Create Quality Recipe Plan
• Create Escalation Plan
• Create recipe layout
• Add Station notifications for Production Line
• Execute Quality Recipe Plan
• View reports

Terminology

Quality Recipe Plan - The plans that are defined in a Quality Recipe. The Quality Recipe Plan also defines the sample rule
that will trigger the creation of a Sample Plan and the Quality Recipe Items for which the plans will be used. (E.g., A company
makes cake. In order for the cake to pass regulations, the eggs must be cooked to over 50°C. The Quality application can be
used to make sure that when the cooked egg is at a work station or a piece of equipment, the temperature is at least 50°C.)

Event Condition - The required condition that must return true in order for a sample plan to be created. Event conditions are
defined in the Quality Recipe Plan. For example, generate a 20 Inch View Panel Sample Plan every 5 minutes; this would be
a “minute timer” event condition.

Standard Plan - The plans initially used once the Sample Plan is created and started.

Escalation Plan - The plans used when the values entered for the Standard Plan fall outside of the acceptable range or fail.

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Login to FactoryTalk Quality Web Interface

1. From the Fit For Purpose applications home page, select the Quality Management icon:

2. Enter username admin and password admin (all lower case) and click Login:

Observe that the FactoryTalk Quality Management Interface consists of two grouped sets of editor buttons:

The first set of buttons are FactoryTalk Quality specific, while the second set of buttons are parts of the configuration that
are common to all three applications (i.e., also applicable to FactoryTalk Performance and FactoryTalk Production). In the
following section we will be examining the common configuration.

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Review the Existing Configuration

1. Click Plant Model:

2. A Plant Model has already been configured on the lab image. Observe the complete Plant Model by fully
expanding the Twinsburg Operations Site tree to the Equipment level:

We have a Site (Twinsburg Operations) and an Area (Operator Interface Area) that contains a Line (View Panel Assemply
Line). The Workcell (View Panel Assembly Line WorkCenter) contains the remaining line equipment. We will be creating
our Quality plan against the View Panel Assembly Line WorkCenter in the following exercises.

3. Click Tag List to view a list of tags to be monitored for data change events:

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 These are all of the control system tags that have already been configured. This interface can be used to import, modify,
and delete tags. In the following lab exercises we will be using RATag1 (CPU_Temp), RATag2 (CPU_Alignment), and
RATag3 (ScreenTest_Result) to collect quality data when testing our 20” panels.

The Part configuration shows the parts that are configured for production. We will not be utilizing this content in the Quality
section of this lab.

4. Select Work Instruction.

Work instruction allows graphics to be imported to describe how to perform the quality testing.

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5. Select the Panel View Screen WI item and then the View button.

A work instruction example will be displayed:

6. Click Work Schedule to display a list of work schedules:

7. From the Work Schedules list box select 2017 WorkSchedule and observe the 3 shifts:

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8. Click Station to see a list of stations and their associated production lines:

A station has already been configured in the image to make it easy to work with the Quality plan created in the upcoming lab
exercises.

9. Click Panel Widget to view the customizable Widgets that provide a graphical user interface (GUI) and can be
run from the Production Execution Client (PEC).

The Panel Widgets are pre-configured and pre-assigned to a Station in this lab. We will be using the Quality Sample Plans
Widget which is assigned to the Quality station from the previous steps.

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10. Click Settings to view the Editor Configuration.

11. Select Change Configuration.

Here we can choose whether to show or hide the common configuration menus that are related to Quality Management.

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12. Click Cancel.
This concludes the application common buttons. In the following exercises we will use
the content specific to Quality Management to create quality checks for a 20 Inch View
Panel manufacturing unit.

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Create Quality Recipe
The Quality Recipe determines what information will be collected, when they should be collected, and visually what the operator
sees when they complete the quality checks.
A Quality Recipe is a configuration object that defines the quality checks to be performed at runtime. Quality Recipes contain
Quality Recipe Items and Quality Recipe Plans. Quality Recipes are defined under a resource, which is an FTPC Plant Model
object (i.e., Site, Area, Production Line, Work Center, or Equipment). A single Quality Recipe can contain multiple Plans and
Items.

1. Select Quality Recipe.

A Quality Recipe has already been created for a 15 inch panel. We’re going to create a new recipe for a 20 inch panel.

2. Select Create.

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3. Name the recipe 20 Inch View Panel. Since this is the first version of this quality recipe and it is for the
Production Line, the rest of the values can be left at their defaults.

After saving the quality recipe we will be taken to the editing screen for the recipe.

4. Now we need to define the resource that this recipe will apply to. Click the Edit button next to Resources and
select View Panel Assembly Line.

The next step is defining the recipe items that we want to capture. A Quality Recipe Item is the data item whose value must
be collected as defined by the Quality Recipe. The method of collection (automatic or manual) is also defined at this level.
Each Quality Recipe has a collection of Quality Recipe Items, which can be associated with zero, one, or multiple Quality
Recipe Plans.

5. Select the Add button under Recipe items.

6. Name the Quality Recipe item CPU Alignment.

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7. Set the following parameters:
• Type: Numeric
• Collected From: Tag
• Requirement Level: Evaluated
• Low Spec Value: -8
• Low Control Value: -6
• High Control Value: 6
• High Spec Value: 8
• Target Value: 0
This will configure the CPU Alignment value to be read from a tag value in the control system at the time of the Quality Plan
evaluation. We’ve also defined what we consider the correct CPU alignment range to be (value is based on a simple
simulated tag in the controller). For the purposes of the lab, any value above -6 and lower than 6 will be considered within
the Quality specifications for this plan.

8. Now we need to define the tag that will be read for the CPU Alignment. Earlier in the lab we looked at all the
tags that were preconfigured for us in this image. Define the controller value that will be used for this item by
selecting the View Panel Assembly Line row and then the tag icon under Tags:

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9. Select RATag2. This is the tag name for the CPU_Alignment tag in the controller.

We have not yet created an escalation plan, we will return to this item configuration after we have created it.

10. Save the Quality Recipe Item.

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11. Create a new Quality Recipe Item named CPU Temperature:
• Type: Numeric
• Collected From: Manual Tag
• Requirement Level: Evaluated
• Tag: RATag1
• Low Spec Value: 73
• Low Control Value: 77
• High Control Value: 83
• High Spec Value: 87
• Target Value: 80
These settings will configure the CPU Temperature to be read from a tag, but as a manual task using a button in the Quality
Plan form when the user is completing the quality test. This is for scenerios where test equipment connected to the control
system is being used to perform quality checks.

12. Create a new Quality Recipe Item named Battery:

• Type: String
• Collected From: Operator
• Requirement Level: Required
• Work Instruction: Logic Board WI
• Boolean True Value: Yes
• Boolean False Value: No
The Battery item will be a String Value that the operator is required to fill out.

13. Create a new Quality Recipe Item named Board Number:

• Type: Numeric
• Collected From: Operator
• Requirement Level: Required
• Work Instruction: Logic Board WI
The Board Number item will be a Numeric Value that the operator is required to fill out.

14. Create a new Quality Recipe Item named Screen Light Bleed:
• Type: Comparison
• Collected From: Operator
• Requirement Level: Evaluated
• Work Instruction: Panel View Screen WI
Comparison will provide the operator with graphical images to use to determine whether the quality check has passed.

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15. To setup the comparison items, use the ‘+’ icon under Comparison to add the lightbleed fail.jpg and lightbleed
pass.jpg items from ‘C:\Users\labuser\Pictures\’.

16. Change the name of the Fault image to Unacceptable Light Bleed and uncheck the Good Value checkbox.

17. Change the name of the Pass image to Acceptable Light Bleed.

18. Create a new Quality Recipe Item named Screen Test Result.
• Type: Boolean
• Collected From: Tag
• Requirement Level: Evaluated
• Tag: RATag3
There should now be 6 Recipe Items configured for the Quality Recipe.

19. Next we’re going to add a recipe plan. Select the Add button under Recipe Plans.

20. Name the plan 20 Inch Screen Test.

Quality Recipe Plans can either be Standard Plans (the basic plan that is run) or Escalation Plans (another plan that is run if
any of the evaluated Quality Recipe Items return a failed value). In this case we’re creating a basic plan first, we will create
an escalation plan later.

21. Now we’re going to define a rule for when a Quality sample will be requested. Under Sample Rule, select the
button next to Event Condition.

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22. There are many ways you can schedule Quality Samples to be taken, but for the purposes of our lab, we’re
going to request that a sample be taken every minute so that we don’t have to wait long to test the Quality
recipe. Select Minute Timer Event for the Type and leave the Period set to 1 minute.

23. We’re going to use all of the recipe items we defined previously, so select the Select All button.

24. Save the Recipe Plan.

Now we’re going to create an escalation plan to run when the quality check fails for the CPU Alignment or the CPU
Temperature. Escalation Plans are optional Quality Recipe Plans that will generate when an item fails a quality check. Each
Quality Recipe Item can be associated with multiple Standard and Escalation Plans.

25. Add a new Recipe Plan named 20 Inch Screen Escalation and select the Escalation Plan checkbox.

26. Change the De-escalation Rule Number of Successes to 2, this means that the escalation plan has to pass
once before we can return to our regular Recipe Plan.

27. Use the Minute Timer Event for the Sample Rule.

28. Select CPU Alignment and CPU Temperature items.

29. Save and Close the Recipe Plan.

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30. Edit the CPU Alignment and CPU Temperature Recipe items adding the escalation plan and priority as shown
below:

Now we’re going to configure what our form looks like for the 20 Inch Screen Test plan.

31. Select the 20 Inch Screen Test Recipe plan and then select Layout.

32. The layout chosen will display during run time in the Sample Plan. Select Layout 4.

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33. Drag and drop the Battery Recipe Item to the first Recipe Items box

34. You will be prompted to choose a widget for displaying this Recipe Item. Leave the first widget selected and
choose OK.

35. Drag and drop the Board Number Recipe Item below the Battery item. (You will see a blue line under the
Operator Scan Widget in the same Recipe items box showing where the new item will be placed).

36. Select the simple field entry widget.

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37. Drag and drop the CPU Temperature Recipe Item to the same Recipe Items box below the Board Number.

38. Select the Gauge Widget.

39. Add the rest of the items to the Layout as shown below. For CPU Alignment select the trend widget:

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40. Click the ‘Title of the Layout’ section and select Properties to edit the layout property values.

41. Change the Title of the Layout to 20 Inch Screen Quality Test and the Font Size to 24.

42. Select Save and View to see the completed form.

Follow the same steps to create a layout for the escalation plan (Note that you will need to save and view the layout in order for it
to save correctly in the Recipe Plan.

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Panel Widget
Panel Widgets are customizable Widgets that provide a graphical user interface (GUI) and can be run from the PEC. The Panel
Widget Quality Sample Plan has already been configured and assigned to a Station for this exercise.
Hint: If a Sample Plan is not generated, go to the Administrator Console and restart the Quality service

Activate Quality Recipe

1. Return to the Quality Recipe page and view the 20 Inch View Panel recipe.

2. Select the Approve button.

3. Select Activate.

4. The effectivity start should be set for today’s date. Choose a date in the future for the End date.

To no longer use the Quality Recipe, you would only need to return to the recipe editor and select the Retired button.

Configure Notifications
Station notifications will alert the user through the web interface when a Sample Plan has been created, completed, failed, or
expired. Once you have your resource hierarchy set up, you can configure notifications for each resource.
If notifications are not available for the existing Station, add Station Notification for the ‘View Panel Assembly Line’ Production
Line.

1. Access the Production Execution Client (PEC) by returning to the Fit For Purpose applications home page or
using the navigation button on the upper-right side of the screen:

2. Change the station by selecting the current station from the menu:

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3. Choose Quality.

4. Select the Quality Sample Plans Panel Widget from the Startable panel.

The Sample Plan Summary screen automatically refreshes based on the Quality Recipe configured.

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5. Scroll down to find the 20 Inch Screen Test Plan items and verify that the standard Sample Plan displays as an
‘Open’ state for the Production Line. (A new test plan should appear every minute based on the minute timer we
configured for the plan)

6. Select a 20 inch sample plan item and then the View button.
You will see that Battery, Board Number, and Screen Light Bleed all have folder icons next to them. Selecting the icon will
open the Work Instruction item that we associated with the Recipe Item.

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7. Enter the Battery and Board Number information, perform a manual read of the CPU Temperature (using the
Read button), and choose an option for screen Light Bleed.

Since CPU Temperature was configured as a manual tag, the operator is required to perform a manual read of the value at
the time of the quality sample. Note that you can also select the folder icons next to Battery, Board Number, and Screen
Light Bleed to see the associated work instruction documents.

8. Save and Complete the Quality check.

9. Verify the result on the Sample Plan Summary screen.

In this case the quality sample failed so all subsequent items have been canceled and the escalation plan has been
activated. We would now need 2 passing escalation checks before we return to our regular 20 Inch Screen Test plan.

Reports
In this section, you will view Quality application Reports. The following reports are provided out-of-box:

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1. From the desktop, double-click the shortcut icon or manually navigate to
http://localhost/Reports/browse/QMReports from your Internet Explorer browser.

Note: The first time this screen is accessed on the lab image you may receive an error message. To correct this, close the
browser and re-open the link from the lab image desktop.
Quality Recipe Configuration Report
The Quality Recipe Configuration Report (QualityCheckConfiguration_V1) displays a table that shows the parameters of the
configured Quality Recipes.

To view the report, select the 20 Inch View Panel Quality recipe from the drop down and then the View Report button on the
right side of the parameters aread.

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Hazard Analysis and Critical Control Points (HACCP) Status Report
The Hazard Analysis and Critical Control Points (HACCP) Status Report (HACCPStatus_V1) displays a table that shows all the
quality checks that were done on a selected machine, Production Line, Area, or Site in specific state(s) during a specified time
range.

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Product Acceptance Report
The Product Acceptance Report (Product Acceptance_V1) displays a table that shows all of the quality checks that were
completed for a selected item. If any of the checks failed, an escalation was enacted. The result of the escalation is that the
quality check reverts back to using a Standard Plan (i.e., back to acceptance).

THIS LAB IS COMPLETE.

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 Notes

Publication XXXX-XX###X-EN-P — Month Year Copyright© 2017 Rockwell Automation, Inc. All rights reserved.
Supersedes Publication XXXX-XX###X-EN-P — Month Year

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