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Creating effective strategies can reduce time-to-market,

lower costs, and improve quality control and business


systems for increased visibility and decision support.
Challenges
Rockwell Automation and IBM Performance Solution provides an
environment that correlates data to synthesize more accurate
indicators such as Overall Equipment Effectiveness (OEE) and
First-Run Quality, which take factory floor events and correlate
them to produce meaningful performance indicators.
It includes automotive business processes and data models,
along with application scenarios that address the major critical
issues facing today's automotive industry, enabling you to quickly
see how implementing this solution will make your business and
manufacturing processes more efficient. These scenarios include:
Just-in-Sequence Scheduling
Locate Vehicle Status Determination
Daily Production Schedule and Calendar
Actual Production Determination
Overall Equipment Effectiveness
Warranty Search on Tracing Information
Manufacturing Constraint Checks
Vendor Managed Inventory
Where Automation and Information Meet
Rockwell Automation and IBMs Performance
Solution integrates automation with business
information systems to provide more data for
better decisions.
Solutions Begin Here
There is a system for every process. But organizational barriers,
varied data acquisition systems and different perspectives often
frustrate the true integration of the wealth of information these
systems generate.
The Rockwell Automation and IBM Performance Solutions
architecture seamlessly bridges the traditional gap between
manufacturing and IT to create a unified view of your total
process data - operations, customers, producers, vendors and
employees. The result: end-to-end business integrationshop
floor to top floor and back again.
Background
Keeping competitive in this fast-paced industry means reacting
quickly to changes in the marketplace and on the plant floor. IBM
and Rockwell Automation have leveraged their combined
capabilities to create an integrated automation and information
solution that goes beyond traditional manufacturing execution
systems (MES) to overcome corporate data organization
boundaries.
First-hand information and metrics culled directly from the
manufacturing floor can be used to provide accurate status and to
better refine availability/ability to promise. These metrics can
also be used for planning and to continuously improve processes.
By providing a unified view of processes and data, as well as
providing data integrity, Rockwell Automation and IBM
Performance Solution delivers real-time connectivity, marrying
MES and production systems to enable actionable response to a
variety of automotive challenges, including:
Assessing current and future plant capability and capacity.
Identifying weak links in the supply chain.
Determining in advance the vehicles affected by component
deficiencies, which help reduce costly and often unnecessary
recalls.
Deciding when to implement new technology or applications.
P|ant F|oor |nfrastructure (Automat|on, Networks, V|sua||zat|on}
FactoryTalk Data Model, XML / WEB Services
FactoryTalk Directory, Live Data, Alarms, Audit
IBM WebSphere Business Integration
Enterpr|se & 8upp|y 6ha|n
8ource Hake 0e||ver
L|ne L|ne
Performance Performance
P|ant P|ant
Performance Performance
us|ness us|ness
Performance Performance
Hach|ne Hach|ne
Performance Performance
Tracking Andon
Error
Proofing
Part Pick
Kitting
Production
Control
Genealogy Sequencing Routing
Quality
Management
Order Flow
Management
Material
Management
Production
Management
Connect Integrate Manage Monitor ModeI
IBM / Rockwell IBM / Rockwell
e e- -Production Production
with WebSphere with WebSphere
Data
Collection
Production
Monitoring
Performance
Analysis
Mining
Reporting
Integrating Rockwell Automation MES Solution To The Enterprise
Features
Rockwell Automation and IBM Performance Solution helps help
eliminate costly inefficiencies in the manufacturing process and
the supply chain. The solution's WebSphere Business Integration
(WBI) for Automotive provides an enterprise-wide scalable
framework, allowing multiple front-end applications to seamlessly
interact with various back-end applications, ensuring internal and
external process integration.
WBI adapters act as mediators between applications, allowing
you to access and exchange information between different
applications and data sources. These adapters can be specific to
an application - such as SAP R/3, version 4 - or to data protocols
like XML or EDI. They can also be accessed through the Internet
for remote access to your integrated systems 24/7/365.
Rockwell Automation's FactoryTalk server with Common Factory
Data Model provides the central repository of relevant factory and
business information, ensuring operational, tactical and strategic
applications have consistent, up to date, and accurate data. The
fully integrated solution achieves efficiencies such as:
Detailed factory floor data to guide purchase planning and
supplier interaction, allowing you to reduce lead-time and
floor stock.
Higher levels of quality and process controls through the
integration of external data and historical data.
Correlation of factory floor events to synthesize more
meaningful performance indicators.
Recording and reporting for warranty claims data and other
information required for compliance with the Transportation
Recall Enhancement Accountability and Documentation Act
(TREAD).
Personalized portals to view data and display alerts/early
warnings, along with interfaces for user decisions or input.
Reuse of your current enterprise networking. Rockwell
Automation and IBM Performance Solution requires no
special networking. It also requires no exclusive hardware,
software, administration or extensive additional training.
Integration with your current enterprise security system.
Publication GMSE00-AP022A-EN-P April 2004
2004 Rockwell Automation Corporation. All rights reserved. Printed in USA.
Plant Floor
Devices
Work Cell
Production
Line
Production
Unit/Area
Site/Plant
Enterprise
0
1
2
3
4
5
Shop Server
Machine Builder
Versa View
ANDON BOARD
Part Call & Part Pick
Ethernet/P
(PC)
(PC)
(PC)
Plant wide Server
Line
Controller
RF Antenna & Tags
Attended
Barcode
Scanner
Barcode
Scanner
Robot
or
Torque
Tool
DeviceNet
Device
Control
nterface
Ethernet
Switch
PDM
Access Point
/O
Ethernet
ERP
HOST
S95 modeI Complete End to End Solution Architecture
Rockwell Automation and IBM Performance Solution is part of Rockwell
Automations complete end-to-end solution for the automotive industry.
In addition to Performance Solution, Rockwell Automation Value
offers several suites of value-added components that span
manufacturing:
Lean Manufacturing
Operational Metrics
Genealogy and Tracking
Part-Vehicle Scheduling Execution System
Quality
Asset Management
Energy Management System
Programmable Device Support (PDS)
Training
Browser or
other Client
Program
External Web
Server /
Value Chain
Server
Bean
Web or J2EE Server
Server
Access
nterface
Data
Format
Handlers
Collaborations
Connector
Controller
Connector
Agent
Connector
Contoller
Connector
Agent
QAD
Connector
Agent
Connector
Controller
SAP
RSLinx
OPC
Plant Floor
Automation
DNet
RS232
RSView - HM
Real-Time
Display
Manufacturing
Performance
Solutions
Enterprise mplementing the BM Automotive Business ntegration
Access Request
Legacy Systems
IBM WebSphere
Off-The-Shelf Solutions
Factory Floor mplementing RA Automotive Manufacturing Solutions Web Services Enabled
ACE & Cisco Network
Link to Design and
Retail/Aftermarket
Deliverable On Demand
2
Delmia
Link to SCM
FactoryTalk
Rockwell Automation/IBM Business Integration Architecture Example

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