To navigate the dynamics of hotly contested global markets and respond flexibly to economic forces, companies are in constant pursuit of savings at every stage of the supply chain. History archive provides basis for real-time decisions Along with operational improvements, one of the keys to savings and optimization is the ability to make well-founded decisions in real time. The APROL PDA history archive holds all recorded production data and serves as a solid foundation for these real-time decisions. APROL BI Suite provides the framework for a manufacturing information system The report server has unrestricted access to all data in the APROL PDA history archive. In addition to evaluating production data collected in real time, it is also possible to integrate external enterprise data (MES, ERP) into the reporting system. Since real-time production data and data from enterprise systems can often have considerable differences, this data can optionally also be extracted, transformed and loaded to the APROL PDA database cyclically.
Correlation analysis helps get to the root of the problem When key operational and production parameters are monitored online and stored in the APROL history archive, correlation analysis can be performed for any time period in order to optimize processes. The ability to differentiate between production data and work order data, scrap data, or operator data through contextualization makes production teams more flexible and allows them to respond more quickly.
The real root of a problem only becomes visible when the process data from machines, lines, equipment and subsystems is viewed in the right context. For this to be effective, it is essential that not only continuous process data, but also event-based data (alarms, messages, operator actions, etc.) are included in the analysis.
Reports deliver key performance indicators The report scheduler can be used to generate all types of reports automatically, such as overall equipment effectiveness (OEE) reports.
The challenge of big data
Studies on the topic of big data forecast up to 40% annual growth in the volume of data generated worldwide. Market trends such as the Internet of Things generate enormous quantities of data – demanding powerful analytical tools to filter useful information from the flood of raw data.
Data is more diverse In the past, logical states, counters, physical parameters and product IDs were generally provided in IEC data types. Today, a growing share of data is provided in a wide variety of non-IEC data types such as PDF, image and video format.
Data is moving faster Faster transmission rates (Gbps instead of Mbps) should not be underestimated as a factor contributing to increased data volumes (terabytes instead of megabytes). Today's controllers come standard with gigabit interfaces, which allow data to be transferred and archived extremely quickly.
All it takes to get an idea of how quickly things are progressing is to compare the volume of data handled by today's process control systems to what the previous generation had to deal with. In the mid-term, managing this sharp increase in data will prove to be one of the greatest challenges for plants of all sizes.
Data is unstructured The majority of data generated in a company exists in a completely unstructured form. Before it can be analyzed, it must first be prepared, filtered and structured. This systematic analysis is crucial to obtaining clear, actionable information from the sea of raw recorded data. And well-informed decisions are the only way to achieve a sustainable increase in productivity.
Ad-hoc reports Different users with different responsibilities need personalized, interactive reports. That's why adhoc reports are becoming increasingly popular as a supplement to standard reports. They give users valuable information and can even be viewed on mobile devices.
One of the dangers of big data is that relevant data can get lost in the shuffle.
Raw data must be prepared, filtered and structured in order to be useful.
Processes must be defined to systematically analyze these huge volumes of data.
Methods such as Online Analytical Processing (OLAP) and data mining make it possible to filter relevant information out of raw data.
Personalized ad-hoc reports supplement standard reports and allow for exploratory analysis that can provide additional insight for decision-making.
APROL - Ready-to-use PDA solution
Virtually every production plant has some way in which it could be operated more effectively and efficiently. With its ready-to-use APROL PDA solution, B&R offers a powerful platform that allows companies to tap this potential easily and conveniently.
Complete networking of all machines and plants plays an indispensable role. From delivery of raw materials to production, packaging and shipping, APROL PDA seamlessly captures operational and production parameters such as environmental conditions, quantities, power consumption, duration, waste and more. APROL PDA then helps operators analyze the recorded data and implement appropriate corrective measures. Efficiency in machine manufacturing Plant operators aren't the only ones looking to maximize efficiency and effectiveness. The goals of continuous, highly reliable operation with minimal downtime and maintenance are shared by machine manufacturers as well. To achieve these goals, both plant operators and machine manufacturers rely on systems for energy monitoring, condition monitoring and process data acquisition.
Based on the APROL process control system, B&R now offers APROL PDA, a ready-to-use solution that comes preinstalled on an Automation PC 910. The APROL automation platform guarantees maximum flexibility with minimal engineering effort. Collecting process data is much easier with APROL PDA than with comparable solutions. Not only controllers programmed with B&R Automation Studio, but also third-party controllers, can be connected via standard fieldbus protocols. 50 to 500,000 data points With the APROL process control system as its underlying platform, APROL PDA is completely scalable and equally suited for the smallest applications with 50 data points or large-scale PDA implementations with several hundred thousand data points. This ensures exceptional long-term protection of your investment. Thanks to its flexible scalability, the system can grow to meet new challenges. Connectivity via Ethernet TCP/IP – Fieldbus modules – I/O modules Controllers programmed in Automation Studio can communicate directly with APROL via gigabit Ethernet. Third-party controllers can choose from a broad selection of fieldbus modules. If additional data points are needed, they can easily and inexpensively be incorporated via remote I/O modules.
Monitor sites around the world
APROL PDA allows you to monitor numerous sites spread all around the world. The local projects all communicate with a central master project. The individual projects can can even have a different release numbers and software versions.
Each location is equipped with an autonomous APROL PDA solution. All monitoring and management functions run directly on site. Poor network connections or low bandwidth do not affect functionality. Local storage of all collected data helps prevent loss and ensure that data is available for analysis at any time.
Shared database Each of the local APROL PDA installations continuously forwards data to the central system, where it is maintained in consistent form in a shared database. Direct access to subsystems Via Linux remote shell access, the master system has direct access to all the functions of the local systems.
Like a pilot's cockpit, the APROL PDA dashboard provides a quick and intuitive overview of key data in speedometers, line diagrams, traffic lights and maps.
Dashboard software makes it possible for users to combine data and graphic indicators and consolidate important information. Multi-report dashboards can also be created using both internal and external data. Web-based design tool Each user can create personalized dashboards by dragging and dropping components in an easy-to-use, web-based design tool. The dashboards can then be modified interactively, giving users the flexibility to quickly optimize the way they view and analyze their data.
Mobile data analysis
With the corresponding app, dashboards and reports can also be viewed on iOS and Android mobile devices. With a touch-capable browser, users can also design custom reports and perform interactive analysis on tablet devices.
Security through server-side authentication The necessary security for smartphones and tablets is guaranteed through server-side authentication.