Rockwell Automation Discrete Machine Performance Solution User Manual

Discrete Machine

Performance Solution

Target Machine Efficiency Improvements

User’s Guide

Doc ID BWDMPS-UM001A-EN-E

Contacting

Rockwell Software

Technical Support Telephone—1-440-646-5800 Technical Support Fax—1-440-646-5801 World Wide Web—www.rockwellsoftware.com

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Warranty

This Rockwell Software product is warranted in accord with the product license. The product’s performance will be affected by system configuration, the application being performed, operator control, and other related factors.

This product’s implementation may vary among users.

This manual is as up-to-date as possible at the time of printing; however, the accompanying software may have changed since that time. Rockwell Software reserves the right to change any information contained in this manual or the software at anytime without prior notice.

The instructions in this manual do not claim to cover all the details or variations in the equipment, procedure, or process described, nor to provide directions for meeting every possible contingency during installation, operation, or maintenance.

1 • Welcome to the Discrete Machine Performance Solution 1

Chapter objectives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

What is the Discrete Machine Performance Solution? . . . . . . . . . . . . . . . . . . . . . . . . . 1

Features and benefits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Intended audience. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

System installer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

System configurator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Line operator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Report user . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Where can I go for help? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Get Discrete MPS training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Get phone support. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Get web support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Get on-site support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Get consulting services. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Contact us . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

2 • Discrete MPS Hardware Installation 7

Chapter objectives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Top and side view. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Before unpacking the computer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Packing list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Shipping/transporting the computer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

European Union Directive compliance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Enclosures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Environmental considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Mounting hardware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Tools required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Mounting dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Mounting clearances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Mounting clearances for the Integrated Display Computer . . . . . . . . . . . . . . . . . 13

Panel cutout dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Panel mounting guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Installing computer in panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Connecting a keyboard and pointing device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Connecting AC power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Connecting to a network . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

iii

DISCRETE MACHINE PERFORMANCE SOLUTION USER’S GUIDE

• • • • •

3 • Initial Operation and Setup 19

Chapter objectives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Operating guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Operator access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Boot-up sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Initial configuration steps. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Using a touchscreen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Touchscreen serial port usage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Driver software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Resistive touchscreen technology. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Calibrating the touchscreen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

4 • Collecting Performance Data 23

Chapter objectives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

What is the OEE rating?. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

User-defined summarization criteria . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Configuring a workcell availability calendar. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Step 1 • Define time patterns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Step 2 • Configure Composite Time Patterns. . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Step 3 • Schedule exceptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

5 • Discrete MPS Configurator Application 35

Chapter objectives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Exploring the user interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

The Configuration Explorer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

The Configuration Work Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

The Configuration Status Bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Main screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

General settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Workcells . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Efficiency Analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Part Counters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Ideal Cycle Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Availability Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Running status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Digital Events. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Multistate Events . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Counters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Breakdown Justification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

Manual Justification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

Automatic Justification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

CONTENTS

Process Variables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Summarization events . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

Strings Localization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

Generating the application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

Workcell Description changes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

6 • Discrete MPS Operator Interface 57

Chapter objectives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

Exploring the Operator Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

Graphical Keyboards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

Main overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

Login . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

Workcell menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

Performance analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

Digital Event . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

Multistate Events . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

Counters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

Process Variable trends . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

Summarization Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

Breakdown justification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

• • • • •

7 • Discrete MPS Reporting 71

Chapter objectives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

Available reports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

Accessing reports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

Report display options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

General toolbar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

Filter toolbar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

Time Selection toolbar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

Time Selection Tools toolbar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

Managing report login accounts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

Report samples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

Performance Analysis OEE Details by Workcell. . . . . . . . . . . . . . . . . . . . . . . . . 79

Performance Analysis OEE Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

Performance Analysis OEE Trend . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

Performance Analysis Production . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

Performance Analysis Production by Shift (text). . . . . . . . . . . . . . . . . . . . . . . . . 83

Performance Analysis Production by Shift (bar chart). . . . . . . . . . . . . . . . . . . . . 84

Digital Events Total Duration (bar chart). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

Digital Events Total Duration (pie chart) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86

DISCRETE MACHINE PERFORMANCE SOLUTION USER’S GUIDE

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Digital Events Number of Occurrences . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87

Digital Events Detailed List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88

Analog Events Total Duration by Day (text) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

Analog Events Total Duration by Day (bar chart) . . . . . . . . . . . . . . . . . . . . . . . . 90

Analog Events Total Duration by Summarization Event . . . . . . . . . . . . . . . . . . . 91

Counters Total by Month (text) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92

Counters Total by Month (bar chart) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93

Breakdowns Total Duration (pie chart) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94

Breakdowns Total Duration by Summarization Event. . . . . . . . . . . . . . . . . . . . . 95

Process Variables Trend . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96

A • System Troubleshooting 97

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97

VersaView Integrated Display Computer problems . . . . . . . . . . . . . . . . . . . . . . . . . . 97

Computer interface problems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98

Index 99

Welcome to the Discrete Machine Performance Solution

Chapter objectives

This chapter provides an overview of the Discrete Machine Performance Solution, the intended audience for this document, and sources of assistance for this product.

What is the Discrete Machine Performance Solution?

Companies in the discrete and repetitive manufacturing industries are being challenged by management to maximize production from existing lines, to meet required cycle-times and delivery dates for each product, and to reduce costs. To meet this challenge, production management is striving to operate the equipment at its highest efficiency.

Real-time identification of production assets that are not performing to a standard is critical to maintaining world-class efficiency. A thorough understanding of the details behind production performance will allow you to identify sources of production inefficiencies and to maximize asset utilization.

Historically, many custom solutions have been developed but have often failed to fulfill expectations, essentially due to problems of long development times, high costs, and lack of configurability.

The Discrete Machine Performance Solution (Discrete MPS) is a pre-developed system, created to provide visualization and analysis of production asset performance based on data acquired from a production control system. The Discrete MPS provides an industrial computer with a standard operator interface application, and the ability to use a remote web browser to access standard reports. The Discrete MPS is built using other successful Rockwell Automation components, and is designed to be configured quickly to match the production configuration or to be re-configured should the production configuration change.

1 • Welcome

Features and benefits

Discrete MPS offers the following features and benefits:

 Calculates the Overall Equipment Effectiveness (OEE) for a workcell to evaluate its

performance.

 Process Event and Process Variable tracking.

 Downtime duration and reason code tracking.

DISCRETE MACHINE PERFORMANCE SOLUTION USER’S GUIDE

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 The ability to track the performance and process data for up to five workcells.

 Visibility and analysis tools for real-time and historical process information.

 Pre-developed Operator Interface displays.

 Pre-developed reports.

 A configuration application used to configure the site-specific production details.

 An entire solution based on a single industrial computer.

Intended audience

This User’s Guide is designed to help you understand how to access and use the Discrete MPS product.

This document is intended for the following types of users:

System installer

This is an individual who installs the Discrete MPS computer and connects it to the plant systems.

This individual should be familiar with:

 Installation of industrial computers on the plant floor  Control systems  Ethernet networking

This user will be most interested in the following chapters of this document:

 Discrete MPS Hardware Installation  Initial Operation and Setup

System configurator

This is an individual who configures the Discrete MPS so that it can capture performance data from the control system and present the real time information to the line operator and the historical reports to the Report User.

This individual should be familiar with:

 Process information (machine, line, and plant)  Control systems  The OEE calculation  The Microsoft Windows operating system

1 • WELCOME TO THE DISCRETE MACHINE PERFORMANCE SOLUTION

This user will be most interested in the following chapters of this document:

 Initial Operation and Setup  Collecting Performance Data  Discrete MPS Configurator Application

Line operator

This is the individual who uses the Discrete MPS Operator Interface on the shop floor. He/she will make use of the Discrete MPS Operator Interface to enter any information that is not automatically collected from the control system and, if required, he will select the proper justification reason for a breakdown.

This individual should be familiar with:

 Process information (machine, line)  Use of a plant floor HMI  Use of a touchscreen

This user will be most interested in the following chapters of this document:

 Discrete MPS Operator Interface

• • • • •

1 • Welcome

Report user

This is the individual who makes use of the reports provided by the Discrete MPS.

This individual should be familiar with:

 Process information (machine, line, and plant)  The Microsoft Internet Explorer Web browser

This user will be most interested in the following chapters of this document:

 Discrete MPS Reporting

Where can I go for help?

Our commitment to your success starts with the suite of learning aids and assistance we provide for the Discrete MPS. You have the following options for getting additional information about this product:

Get Discrete MPS training

One of the best ways to increase your proficiency at using Rockwell Software products is to attend Rockwell Software training programs. Our training programs can help you master the basics and show you how to unleash the full potential of our software.

DISCRETE MACHINE PERFORMANCE SOLUTION USER’S GUIDE

• • • • •

We offer a wide range of training programs, from regularly scheduled classes conducted at Rockwell Software facilities, to custom-tailored classes conducted at your enterprise. The size of each class is kept small intentionally to maximize student engagement.

If you would like more information about our training programs, visit the Rockwell Software site on the World Wide Web or contact the Rockwell Software Training Coordinator. Our World Wide Web address and telephone numbers appear on the inside front cover of this document.

Get phone support

Rockwell Software’s support team of outstanding professionals provides top-notch technical support — monitoring and tracking your experience with our products to pave the road to your success in understanding and improving your factory performance.

Questions concerning installation and the use of the software are handled by the Rockwell Automation Customer Support Center, staffed Monday through Friday — except U.S. holidays — from 8 AM to 5 PM Eastern time zone for calls originating within the U.S. and Canada.

To reach the Customer Support Center, call 440-646-5800 and follow the prompts. For calls originating outside the U.S./Canada, locate the number in your country by visiting support.rockwellautomation.com

and selecting the Phone Support link.

HEN YOU CALL

When you call, you should be at your computer prepared to give the following information:

 your a support contract number  the type of control system hardware you are using  the exact wording of any errors or messages that appeared on your screen  a description of what happened and what you were doing when the problem occurred  a description of how you attempted to solve the problem

Get web support

In addition to phone support, the Rockwell Automation Customer Support Center offers extensive online knowledgebases of tech notes and frequently asked questions for support of non-urgent issues. These databases are updated daily by our support specialists.

To receive regular e-mail messages with links to the latest tech notes, software updates, and firmware updates for the products that are of interest to you or to submit an online support request, visit support.rockwellautomation.com/supportrequests

1 • WELCOME TO THE DISCRETE MACHINE PERFORMANCE SOLUTION

Get on-site support

Rockwell Automation field support engineers are located around the globe to provide assistance with special projects, unexpected problems, or emergency situations on-site. Field support engineers are available for dispatch 24x7x365 and can arrive at many locations the same day.

To learn more about this and other support services, visit support.rockwellautomation.com

Get consulting services

Rockwell Automation provides expert consulting and turnkey implementation of the RSBizWare suite. Please contact your local representative for more information.

Contact us

We strive to help all of our customers become successful in their manufacturing improvement efforts. Toward this objective, we invite you to contact your local representative or Rockwell Software at any time that we may be of service to you.

• • • • •

1 • Welcome

DISCRETE MACHINE PERFORMANCE SOLUTION USER’S GUIDE

• • • • •

Discrete MPS Hardware Installation

Chapter objectives

This chapter describes installation of the VersaView Integrated Display Computer.

Features

The following illustrations show the major features and controls of the VersaView Integrated Display Computer.

Top and side view

2 • Installation

DISCRETE MACHINE PERFORMANCE SOLUTION USER’S GUIDE

• • • • •

Note: The VersaView that ships with the Discrete MPS has two PS/2 ports.

Before unpacking the computer

Before unpacking your new computer, inspect the shipping carton for damage. If damage is visible, immediately contact the shipper and request assistance. Otherwise, proceed with unpacking.

Make sure you keep all the original packaging for the computer in case you need to return the computer for repair. Both the inner and outer packing cartons should be used to ensure adequate protection for any units returned for service.

Packing list

 Computer with operating system pre-installed  Microsoft XP Pro License  Mounting clips  AC power cord  Accessories CD-ROM (red) containing touchscreen driver, video drivers, Ethernet

drivers, and technical documentation

 Recovery CD-ROM (blue)  Quick Start guide

Shipping/transporting the computer

If, after you have installed the VersaView computer, you must ship it via common carrier or otherwise transport it to another location, you must first remove the unit from the panel and place it in its original packing material.

Do not ship or otherwise transport the VersaView computer while it is installed in a door or panel. You must uninstall the computer and place it in its original packing material before shipping or transporting the unit. If you ship or transport the computer while it is installed in a door or panel, you may severely damage the unit. Rockwell Automation is not responsible for damage incurred to the computer if it is shipped or transported while still installed in a door or panel.

European Union Directive compliance

The VersaView Integrated Display Computer meets the European Union Directive requirements when installed within the European Union or EEA regions and has the CE mark. A copy of the Declaration of Conformity is available at the Rockwell Automation / Allen-Bradley Internet site: www.ab.com

The VersaView Integrated Display Computer is intended to operate in an industrial or control room environment, which utilizes some form of power isolation from the public low voltage mains. Some VersaView computer configurations may not comply with the EN 61000-3-2 Harmonic Emissions standard as specified by the EMC Directive of the European Union. Obtain permission from the local power authority before connecting any VersaView computer configuration that draws more than 75 watts of AC power directly from the public mains.

• • • • •

2 • DISCRETE MPS HARDWARE INSTALLATION

2 • Installation

To comply with EN 55024, the Ethernet LAN cable must be less than 30 m [98.42 ft.] long, and it must only be used indoors (i.e., not exit the building at any point). All other I/O cables must be less than 3 m [9.842 ft.] long, and must only be used indoors.

Enclosures

Mount the VersaView Integrated Display Computer in a panel or enclosure to protect the internal circuitry. Versions with a gestated bezel meet NEMA Type 1, 12, 4, 4X (indoor

DISCRETE MACHINE PERFORMANCE SOLUTION USER’S GUIDE

• • • • •

use only) and IEC IP66 only when mounted in a panel or enclosure having an equivalent rating.

Environment and enclosure

This equipment is intended for use in a Pollution Degree 2 industrial environment, in overfatigue Category II applications (as defined in IEC publication 60664-1), at altitudes up to 2000 meters without darting.

This equipment is considered Group 1, Class A industrial equipment according to IEC/CISPR Publication 11. Without appropriate precautions, there may be potential difficulties ensuring electromagnetic compatibility in other environments due to conducted, as well as radiated, disturbance. This equipment is supplied as “open type” equipment. It must be mounted within an enclosure that is suitably designed for those specific environmental conditions that will be present and appropriately designed to prevent personal injury resulting from accessibility to live parts. The interior of the enclosure must be accessible only by the use of a tool. Subsequent sections of this publication may contain additional information regarding specific enclosure type ratings that are required to comply with certain product safety certifications. See NEMA Standards publication 250 and IEC publication 60529, as applicable, for explanations of the degrees of protection provided by different types of enclosure. Also, see the appropriate sections in this publication, as well as the Allen-Bradley publication 1770-4.1 (

Grounding Guidelines

), for additional installation requirements pertaining to this equipment.

Industrial Automation Wiring and

Environmental considerations

Follow these guidelines to help ensure that the computer provides safe and reliable service.

 Ensure that sufficient space is available around air inlets and outlets to provide the

circulation necessary for cooling. Never allow air passages to become obstructed.

 Allow enough room within the enclosure for adequate ventilation. The ambient

temperature around the computer must be between 0-50 °C (32-122 °F). Also

consider heat produced by other devices in the enclosure. You may need a usersupplied fan, heat exchanger, or air conditioner to meet this condition in some installations.

Remember that heat rises. The temperature at the top of an enclosure is often much higher than the rest of the enclosure if air is not circulating.

The VersaView Integrated Display Computer is designed to operate at a range of extremes. However, it is not good design practice to continuously operate the computer at the highest end of the specified temperature range. While the product will operate at its highest specified temperature, the overall life span of any electronic device is shortened when it operates at its highest rated temperature.

Ensure that the humidity of the ambient air will not exceed specified limits. In very dry environments, static charges build up very readily. Proper grounding of the equipment through the AC power cord can help reduce the likelihood of static discharges, which may cause shocks and damage electronic components.

Leave the computer’s enclosure or cover in place at all times during operation. The cover affords protection against high voltages inside the computer and inhibits radio-frequency emissions that might interfere with other equipment.

Mounting hardware

The VersaView Integrated Display Computer is shipped with 10 mounting clips, which are used for mounting in a panel or enclosure.

• • • • •

2 • DISCRETE MPS HARDWARE INSTALLATION

2 • Installation

Tools required

In addition to the tools required to make the cutout, you will need a #2 Phillips screwdriver.

Mounting dimensions

The following figures show mounting dimensions for the VersaView Integrated Display Computer. Dimensions are in mm [in]:

DISCRETE MACHINE PERFORMANCE SOLUTION USER’S GUIDE

• • • • •

Mounting clearances

Allow adequate space for mounting, air flow, and maintenance. The figure below shows recommended minimum clearances to other components within the rack or enclosure.

The VersaView Integrated Display Computer should not be operated within a confined space of the dimensions shown below unless adequate ventilation or other cooling methods are used to lower the air temperature within the enclosure.

2 • DISCRETE MPS HARDWARE INSTALLATION

Mounting clearances for the Integrated Display Computer

• • • • •

2 • Installation

DISCRETE MACHINE PERFORMANCE SOLUTION USER’S GUIDE

• • • • •

Panel cutout dimensions

Panel mounting guidelines

Observe the precautions below when installing the computer in a panel:

 Confirm that there is adequate space behind the panel. A cabinet with a minimum

depth of 127 mm (5.0 in) is sufficient.

 Supporting panels should be at least 14 gauge to ensure proper sealing against water

and dust and to provide proper support. The mounting hardware supplied accommodates panels up to 6.25 mm (0.25 in) thick.

Supporting panels must be cut to specifications before installation.

Installing computer in panel

To install the computer in a panel using mounting clips:

Disconnect all electrical power from the panel before making cutout.

Make sure area around the panel cutout is clear.

Take precautions so that metal cuttings do not enter any components that are already installed in the panel.

Failure to follow these warnings may result in personal injury or damage to the panel components.

2 • DISCRETE MPS HARDWARE INSTALLATION

1. Cut an opening in the panel using the appropriate panel cutout dimensions provided above.

2. Make sure the computer sealing gasket is properly positioned on the terminal. This gasket forms a compression-type seal; do not use sealing compounds.

3. Place the computer in the panel cutout.

4. Install the mounting clips. The mounting clips slide into the slots on the top, bottom and sides of the computer.

• • • • •

2 • Installation

DISCRETE MACHINE PERFORMANCE SOLUTION USER’S GUIDE

• • • • •

5. Gradually tighten the clips one at a time around the bezel using the specified sequence. Note that the sequence begins with the center clips and continues to the corner clips.

Repeat this process at least three times until the clips are hand-tight and the gasket is compressed uniformly against the panel.

Tighten mounting clips to a torque of 10 in-lbs (1.1 N•m) in the sequence shown above. Do not over-tighten.

Tighten mounting clips to a torque of 10 in-lbs (1.1 N•m) to provide a proper seal and prevent damage to the VersaView computer. Rockwell Automation assumes no responsibility for water or chemical damage to the terminal or other equipment within the enclosure because of improper installation.

Connecting a keyboard and pointing device

A keyboard and pointing device can be plugged individually into the PS/2 port on the bottom of the computer. There are separate PS/2 ports for the keyboard and the pointing device.

Connecting AC power

A standard IEC 320 power cord provides power to the VersaView Integrated Display Computer. The power supply input will accept 120/240V AC. The power supply is autoswitching. Ensure that sufficient power is available.

Select an electrical outlet carefully before plugging in your computer:

The power cord must be connected to an outlet having an earth ground (three-prong outlet). Failure to follow this warning could result in severe electrical shock.

Installing computer in a panel, enclosure or rack that is already connected to earth ground will satisfy this requirement. Otherwise, connect your computer to earth ground using a 16 AWG or larger external wire.

The ground wire should have green insulation with a yellow stripe for easy identification.

The outlet should have its own disconnect. Do not plug the computer into an outlet that is connected to the main electrical disconnect.

To prevent problems resulting from power surges or unexpected power failure, protect the outlet with its own fuses or circuit breakers, as well as an Uninterrupted Power Supply (UPS) system.

• • • • •

2 • DISCRETE MPS HARDWARE INSTALLATION

2 • Installation

Always shut down the operating system prior to removing power. Failure to do so will cause performance degradation and eventual failures in the operating system.

Connecting to a network

The VersaView Integrated Display Computer accommodates CAT5 twisted pair Ethernet cabling with RJ45 connectors to support 100 Mbps network data transfer.

Performance degradation of your Ethernet communications is likely to result if the unit or cables are subjected to extreme radiated or conducted high-frequency noise. It is the user’s responsibility to properly route cables and condition input power in order to improve communication reliability. Proper cable routing and power conditioning is required to ensure reliable Ethernet communications in industrial environments. Rockwell Automation recommends that all Ethernet cabling be routed through dedicated metal conduits. Installing ferrite bead filters at cable ends may also improve reliability.

DISCRETE MACHINE PERFORMANCE SOLUTION USER’S GUIDE

• • • • •

Initial Operation and Setup

Chapter objectives

This chapter discusses initial setup procedures and operation of the system.

Operating guidelines

We recommend the following operating guidelines for the VersaView Integrated Display Computer:

 Avoid turning the system on and off frequently.

 Always use the proper power down procedures as required by your operating system,

such as the Shut Down command in Microsoft® Windows.

 Do not turn off the computer until a message appears telling you that it is safe to do so.

 Do not operate the VersaView Integrated Display Computer with covers removed. An

electrical shock hazard exists. In addition, removing the covers will disrupt air flow and may result in overheating. All covers are required to maintain EMI shield.

After shutting the system off, do not move the computer or turn it back on again until the hard drive has come to a complete stop (it takes about 30 seconds).

Operator access

3 • Setup

Operator access is limited to the front panel of the VersaView computer. This includes the display and touchscreen. Access to components behind the rack or panel in which the computer is installed is restricted to authorized and properly trained personnel.

Boot-up sequence

To boot up the system:

1. Apply power to the VersaView computer. The computer performs a Power On Self Test (POST) in which it tests the processor board, memory, keyboard, and certain peripheral devices.

2. The computer displays the progress of the POST and initialization of accessory devices.

DISCRETE MACHINE PERFORMANCE SOLUTION USER’S GUIDE

• • • • •

3. If your system does not boot up, after previously booting successfully, refer to the VersaView 6181P Integrated Display Computers User Manual for diagnostic and troubleshooting information.

4. The computer will then display the startup dialogs for the operating system that has been installed.

Initial configuration steps

During the first initial boot of the computer, several configuration windows are shown and must be completed.

1. Initially, the Windows 2000 Professional splash screen is shown. A progress bar at the bottom indicates startup progress.

2. A Windows 2000 Setup dialog box opens with the message “Please wait…” After about 20 seconds this dialog will close automatically.

3. The Windows 2000 Professional Setup dialog box opens with the message “Welcome to the Windows 2000 Setup Wizard.” Select Next to continue with the setup.

4. On the License Agreement dialog window, read the terms of the agreement. Select I accept this agreement and then select Next to continue.

5. On the Regional Settings dialog window, customize the Windows locale setting and keyboard layout if necessary. US English settings are the defaults; no changes are necessary to select these. Select Next to continue.

6. On the Personalize Your Software dialog window, enter a Name and Organization that the Windows Operating System will use as the identification for various operations. Select Next to continue.

7. On the Computer Name and Administrator Password dialog window, enter the Computer Name that has been assigned to identify this computer on the network and enter the password to use for this computer's Administrator user account. Select Next to continue.

After the Discrete MPS on-site services are completed, do not change the computer name assigned to the computer. Changing the computer name will prevent the Discrete MPS from functioning properly.

8. On the Date and Time Settings dialog window, set your local date, time and time zone for the system clock. Select Next to continue.

9. On the Workgroup or Computer Domain dialog window, assign the computer as a member of the appropriate Domain or Workgroup for your network. Select Next to continue.

If your computer is being placed on a domain you will be prompted for a network administrator login.

After network configuration, the computer will automatically restart and attempt to log in with the administrator user account.

After rebooting, complete any network configuration required for the computer. By default, the computer is configured to obtain an IP address automatically (dynamically obtain an IP address from a network server).

After the Discrete MPS on-site services are completed, do not change the password for the administrator user account. Changing the password for the administrator user account will prevent the Discrete MPS from functioning properly.

Using a touchscreen

The VersaView Integrated Display Computer is equipped with a touchscreen. The touchscreen and the touchscreen controller are both factory installed and connected.

• • • • •

3 • INITIAL OPERATION AND SETUP

3 • Setup

Touchscreen serial port usage

The touchscreen controller for a VersaView computer connects internally to the COM2 serial port. The touchscreen is factory configured with the proper COM2 and touchscreen driver settings, so no user configuration is required.

If for any reason these settings are corrupted, reset the COM2 serial port to 9600bps, 8 data bits, 1 stop bit, no parity.

Driver software

The touchscreen driver is already loaded on the computer. The driver software is also provided on a floppy diskette.

The touchscreen utility defaults to COM1 serial port setting. You must change this setting to COM2 when reloading the touchscreen driver.

Resistive touchscreen technology

Resistive touchscreens are activated by pressure applied to the touchscreen by an operator’s finger. You can operate a resistive touchscreen while wearing gloves.

DISCRETE MACHINE PERFORMANCE SOLUTION USER’S GUIDE

• • • • •

Resistive touchscreens consist of two layers:

 A lower layer (glass substrate) with a resistive coating and a voltage applied.  An upper layer (cover sheet) with a conductive coating.

Clear spacer dots separate the two layers.

When a user presses the upper layer onto the lower layer, the upper layer receives the voltage applied to the lower layer. The touchscreen controller detects the change in voltage on the upper layer and alternates voltage horizontally and vertically through the layers. The voltage transferred to the upper layer is proportional to the location of the touch on the screen.

Do not use sharp instruments to activate the touchscreen. Scratching the surface of the touchscreen can damage the unit.

Calibrating the touchscreen

The touchscreen supplied with the VersaView computer is factory installed and calibrated. In the event that you need to recalibrate the touchscreen, use the following procedure:

To calibrate the touchscreen:

1. Locate the calibration utility in the Control Panel or insert the touchscreen driver diskette in the floppy drive of the computer.

2. Using the appropriate commands for your operating system, run the calibration utility.

3. Follow the instructions in the calibration utility to complete the calibration process.

Collecting Performance Data

Chapter objectives

This chapter provides an description of some of the concepts and configuration necessary to collect performance data using the Discrete MPS.

The

Discrete MPS Configuration Workbook

for determining the information necessary to configure the Discrete MPS.

What is the OEE rating?

Discrete MPS uses an OEE (Overall Equipment Effectiveness) model to measure the performance of manufacturing equipment. The OEE model yields a single performance rating for every activity area (workcell, line, area, or plant) being monitored, thereby providing a simple way to determine quickly if an activity area is performing adequately. The OEE value can be used to assess a single machine’s performance over time or to compare the performance of machines to each other.

Three components contribute to an OEE value: availability, throughput, and quality. Each is a percentage, and the OEE value is the product of these three percentages, and therefore is also a percentage.

Availability is the ratio of running time to available time. Available time may be defined by a schedule or modified by planned downtime events such as preventive maintenance. Available time may also be modified by events, such as being starved for parts or being blocked by a downstream process.

Availability RunningTime AvailableTime⁄=

Excel file provides a step-by-step process and tips

4 • Performance Data

Throughput is the performance of a machine when it is running compared to its ideal cycle time. The ideal cycle time will depend upon the product being produced and is measured in units of seconds per part.

Throughput TotalParts IdealCycleTime×()RunningTime⁄=

Quality is the percentage of good parts that are produced.

GoodParts TotalParts Scrap–=

Quality GoodParts TotalParts⁄=

The OEE calculation that is used by Discrete MPS is the product of these three components:

DISCRETE MACHINE PERFORMANCE SOLUTION USER’S GUIDE

• • • • •

OEE Availability Throughput

RunningTime

OEE

-----------------------------------------

AvailableTime

× Quality×=

TotalParts IdealCycleTime×

---------------------------------------------------------------------------------

This reduces to:

OEE

IdealCycleTime GoodParts

----------------------------------------------------------------------------------=

AvailableTime

Discrete MPS gathers and stores all of the raw data necessary to make this calculation for specific time periods, as well as by activity area, by part number, and by shift. All of the individual components of the calculation are stored and available for analysis.

OEE is a valuable method of analyzing performance because it is widely recognized and can be applied to any type of industry, factory, or machine. Further, Discrete MPS supports the collection of detailed event data, which can be used to analyze the specific causes of inefficiencies.

Refer to “Efficiency Analysis” on page 39 for a description of how to configure Discrete MPS to determine OEE.

User-defined summarization criteria

A summarization criterion is a Discrete MPS Performance Parameter field for which activity area data can be collected. When the value of the field changes, it triggers the summarization of historical performance data for the activity area in the Discrete MPS Workcell report data source. The collected values can then be used to filter OEE performance data for the activity area. For example, if your system is configured to collect Part ID (a default summarization criterion) for an activity area, you will be able to calculate the OEE performance for the activity area when it is producing a particular kind of part. In addition to the default summarization criteria — Shift, Part ID, and Ideal Cycle Time — for which Discrete MPS can collect data values, you can configure up to five user-defined summarization criteria, or flex fields, to represent the fields that are most important to your organization. User-defined summarization criteria function just as the default summarization criteria do, but, because they are user-defined, they allow you to tailor Discrete MPS to meet your organization’s data collection and summarization needs.

RunningTime

GoodParts

------------------------------

×=

TotalParts

The following are sample uses of user-defined summarization criteria:

 An Operator ID user-defined summarization criterion that will allow you to collect

operator IDs and to report on the OEE value for a specific operator.

 A Lot Number user-defined summarization criterion that will allow you to collect lot

numbers and report on the OEE value for a specific lot of products.

+ 76 hidden pages

Rockwell Automation Discrete Machine Performance Solution User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Contents

Welcome to the Discrete Machine Performance Solution

Chapter objectives

What is the Discrete Machine Performance Solution?

Features and benefits

Intended audience

System installer

System configurator

Line operator

Report user

Where can I go for help?

Get Discrete MPS training

Get phone support

Get web support

Get on-site support

Get consulting services

Contact us

Discrete MPS Hardware Installation

Chapter objectives

Features

Top and side view

Before unpacking the computer

Packing list

Shipping/transporting the computer

European Union Directive compliance

Enclosures

Environmental considerations

Mounting hardware

Tools required

Mounting dimensions

Mounting clearances

Mounting clearances for the Integrated Display Computer

Panel cutout dimensions

Panel mounting guidelines

Installing computer in panel

Connecting a keyboard and pointing device

Connecting AC power

Connecting to a network

Initial Operation and Setup

Chapter objectives

Operating guidelines

Operator access

Boot-up sequence

Initial configuration steps

Using a touchscreen

Touchscreen serial port usage

Driver software

Resistive touchscreen technology

Calibrating the touchscreen

Collecting Performance Data

Chapter objectives

What is the OEE rating?

User-defined summarization criteria