Visualizing Data for Improved Repeatability8 min video / 2 minute read
- 400 tags per machine (typical installation is five or more machines)
- Approximately 15 screens (varies according to Overbridge module)
- More than 20 clients open at any given time, typically
- Usually more than 100 alarms (in two categories: process alarms and recipe-deviation alarms)
- Usually 3 devices per machine
- Standard Architecture, Redundant
- Usually 50 historical data points per machine
- SQL Server and Oracle databases
Problem: Roll manufacturing is a unique process due to the geometry of a wound roll making it difficult to analyze the wind properties of a roll. Due to the number of variables involved in manufacturing a roll, it has been extremely difficult to perform root cause analysis of roll properties and performance as these are not available until a roll unwinds.
Roll manufacturing has tended to be a craft-based industry with an aging work force. As the current operators are retiring, the knowledge is going out the door with the operator. There is a need to capture the craft knowledge in a context-driven, searchable electronic format for reference and training purposes.
Solution: RollDVR allows virtual replay of the roll wind in, and in reverse mode, visualization of how the roll will wind out. RollDVR provides deep-drill click visualization and analysis of roll manufacturing wind-in and wind-out properties. The project allows roll build replay with direct association of machine process points, recipe settings, and time series charting using a slider on a scaled vector graphic to select point-of-time for display. Through the use of a best-fit algorithm, roll-to-roll process point comparison is available to assist in root cause analysis.
The RollDVR recipe editor provides the ability to tune the recipe in context of the point-in-time manufacturing issue presented in the visualizer. Additionally, the built-in Knowledge Base Collection Manager creates a means to annotate analysis and create a searchable contextual repository for training and reference purposes.
Benefits: The user is able to use logic in context to determine the manufacturing properties of a roll. There is no more guessing, and rolls are replayed and analyzed prior to downstream processes, creating great efficiency due to quantifiable parameters such as run-ability. Additional benefits include upstream process traceability and chain-of-custody management. The knowledge base has proved to be a valuable item for bringing science and repeatability to what was once a craft-based process.