Wonderware Intelligence software – sample (and simple) scenario

Here’s a sample dashboard created using Wonderware Intelligence software.

The dashboard has been created around a scenario of a manufacturing company described below:

1. Scenario

Such a company would have a number of information systems such as:

  • financial accounting system (or invoicing system) – such system would provide information about sales volume along with profit margin attained
  • production tracking system (implemented as either, off-the-shelf solution such as Wonderware Operations, or as a 3rd party or custom solution) – this system could provide information about planned and actual production volume broken down by product, production line, machine etc. This system could also provide some quality information (e.g. material dimensions or other characteristics)
  • traditional HMI/SCADA system – which could provide some information about equipment utilization (e.g. downtime vs. uptime) and energy consumption (so that comparison between nominal energy consumption and the actual usage could be performed)

Coming our of the current recession, the leadership of the company would like to get some information about their system to make smart decisions. They would like to know current and historical values of:

  • financials – sales and margin, broken down by customer and product
  • production schedule attainment broken down by shift
  • equipment efficiency by production line and individual machines
  • energy usage by line and machine

This is where using Wonderware Intelligence software we can create data repository that combines and correlates information from all the data sources listed above.

2. Wonderware Intelligence software – server side

Wonderware Intelligence comes with a set of connectors to other products such as:

  • Wonderware Historian (formerly called IndustrialSQL Server or InSQL),
  • OSI Pi,
  • Oracle,
  • obviously generic Microsoft SQL Server
  • and CSV files.

These connectors allow the Intelligence Server to import data on regular basis from the production system and put it in the Intelligence own data store (this way when run the reports we don’t tax the production system and data retrieval is much faster as the data is pre-aggregated).
Information model created in Wonderware Intelligence has a form of multidimensional cube that allows us to slice and dice information according to our criteria. The model has three major components:
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  • data sources – they define how to connect to our data (e.g. financial accounting system or plant data historian system)
  • dimensions – they define our criteria (such as shift, product, customer etc)
  • measures – they define value we want to measure or analyze (sales volume, production volume etc)

Shown here is a sample screenshot of Wonderware Intelligence data model in the ArchestrA IDE (Integrated Development Environment) used by Wonderware System Platform.

After all these data sources, dimensions and measures have been defined, users can connect to them using Wonderware Intelligence Analytics Client – very easy to use and very powerful software that can be used directly by people who need the reports.

3. Wonderware Intelligence software – power user experience

image In the Intelligence Analytics Client environment, the user is presented a very intuitive data model that consists of dimensions and measures (as shown here). No need to know Transact SQL programming language, no need to get access to the production system, no need to know how to calculate daily total based on 1-minute data etc.

The user is presented with a list of dimensions and measure and all we need to do is drag appropriate parameters to the worksheet. We can add filters, change sorting, change colors and much more, all using point and click user interface.

What’s important is that the report users can create reports for themselves without waiting for their IT departments. They can save the reports locally in a way similar to saving Excel files and they can share them with other users.

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The user can create multiple worksheets and then lay them out on a dashboard.

Finally the dashboard can be published to the Intelligence Dashboard Server – just like the dashboard with which we started this posting.

4. Intelligence Dashboard

So let’s talk about the presented dashboard. It consists of four distinct parts:

  • Sales and Margin Contribution (upper left chart) – this report shows sales distribution per customer and per product expressed as a square – the bigger the square size is, the greater the sales volume is. On top of that, the color of the square represents our margin – red means low margin, green means good margin. How easy is it to figure out that we’re having a bit of a margin issue with products COO250 and COO378 – for some reason our margin on them is lower than on other products.

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  • Equipment Efficiency (upper right chart) – this report shows efficiency for each machine in the system. So it looks like Coffee Line has much lower efficiency comparing to any other line.

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  • Production Schedule Attainment (lower left chart) – this report shows how each shift attains their given production schedule. Well, it looks like the night shift may not be pulling its weight as much as it should.

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  • Energy Deviation (lower right chart) – this report show the difference between expected energy usage and the actual energy usage.

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5. Summary
All these concepts are very similar to multidimensional business intelligence systems such as Microsoft Analysis Services. But few things make Wonderware Intelligence look interesting:

  • most configuration steps can be performed without advanced programming knowledge.
  • conceptually Wonderware Intelligence’s model is a cube, but it’s implemented using a de-normalized SQL Server database which makes it really easy to query using regular client tools
  • finally, the dashboard creation environment is very easy to use by non-IT people (e.g. production engineers, quality personnel etc.)

Performance Information Technologies provides consulting services related to reporting, plant & business intelligence and technology integration solutions for your plant or process. Contact us at greg.dubiel@perfinfo.com or (425) 440-0626.

Wonderware Tech Note 726 “Capturing a Memory Dump File Using the Microsoft® Debug Diagnostic Tool (32bit)”

Wonderware released Tech Note 726 “Capturing a Memory Dump File Using the Microsoft® Debug Diagnostic Tool (32bit)”. This Tech Note details how to use the Debug Diagnostic Tool (DebugDiag) for troubleshooting issues such as hangs, slow performance, memory leaks or fragmentation, and crashes in any user-mode process. The tool includes additional debugging scripts for Internet Information Services (IIS) applications, web data access components, COM+ and related Microsoft technologies.

The Tech Note is available on the Wonderware Developer Network (WDN) website at https://wdnresource.wonderware.com/support/kbcd/html/1/t002501.htm

Free webinar on Wonderware Intelligence software available

As I informed earlier, Wonderware PacWest hosted a free webinar on the Wonderware Intelligence software on May 25th, 2010. Here’s a brief description of Wonderware Intelligence software.
I had a pleasure of being a presenter and a guest speaker during this webinar. For those customers of Wonderware PacWest who missed the presentation, it was recorded and is now available for download on the Wonderware PacWest website at http://www.pacwest.wonderware.com/web/Training/OnlineSeminars.aspx#Intelligence.
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Free Wonderware PacWest website login account is required to download the seminar (newly registered users – please allow 1 business day before attempting to download the seminar as your registration needs to be verified).
Non-PacWest customers are out of luck here, but I am available to speak about Wonderware Intelligence or any other Wonderware software. Just contact me at greg.dubiel@perfinfo.com

Wonderware Historian’s retrieval modes – free technical whitepaper from Wonderware North

Wonderware North released their Tech Tip on Wonderware Historian’s retrieval modes entitles “Wonderware Historian – A Look At Different Data Retrieval Methods”. The documents describes various retrieval modes of Historian in relation to data acquisition and it also compares built-in retrieval modes of Historian with standard Transact SQL aggregate functions.

The document can be found on the Wonderware North website.

Wonderware Application Server script attributes

The following table describes the scripting attributes available in Wonderware Application Server (aka Wonderware System Platform, aka ArchestrA software) version 3.x for each script defined in the Galaxy:

Attribute Description Run-Time Access (Supervisory, User, Read-Only, None)
<Script>.AsyncShutdownCmd If set to TRUE, the currently executing asynchronous script will be requested to shut down. This does not mean that the script actually will shut down. The script must be written to check this flag. Supervisory, User
<Script>.Disabled If set to TRUE, the calculation of the expression and the execution of the script code will be stopped. Supervisory, User
<Script>.ErrorCnt The number of errors detected for this script since last reset. Read-Only
<Script>.ExecutionCnt The number of times this script has executed since the last reset. Only applies to Execute type scripts, both synchronous and asynchronous. Read-Only
<Script>.ExecutionError.Condition If TRUE, the script engine encountered an error, such as divide-by-zero, .NET error or execution timeout) during last execution. This attribute can be alarmed. If alarmed, the alarm message is ExecutionError.Desc. Read-Only
<Script>.ExecutionError.Desc The error message associated with the execution error condition. Read-Only
<Script>.ExecutionTime The amount of time, in milliseconds, the script has been executing for asynchronous scripts. For synchronous scripts, this attribute reflects the time of the last execute. When the script has finished executing, the value remains at the final elapsed time for the script. When the script is restarted, this value is reset to zero (0). Read-Only
<Script>.ExecutionTimeAvg The average per scan execution time, in milliseconds, since the script was last reset. Read-Only
<Script>.ExecutionTimeStamp The last time the script executed. Read-Only
<Script>.State Indicates the state the object’s script is in: Initializing, Error, Disabled, Busy, Ready.

  • Initializing indicates at least one of the script’s external references in the script expression is still initializing.
  • Error indicates an error occurred since the last time the script was triggered.
  • Disabled indicates the script execution was disabled.
  • Busy indicates that the script is currently executing (only applies to asynchronous scripts).
  • Ready indicates that an asynchronous script is not currently executing or that a synchronous script is not in an error or disabled state.
Read-Only
<Script>.StatsReset If set to TRUE, all statistics will be set to zero. Supervisory, User

Wonderware product version information

Do you want to know what’s the latest version of the Wonderware product you’re using? Or do you want to know what’s the latest update (service pack or patch) for the version you’re currently using?
The answer is the Product Version page hosted on the Wonderware PacWest Website.
The page lists all the major Wonderware products (such as InTouch, IndustrialSQL Server Historian, ActiveFactory etc.) and for each of the product a version trail information is provided as shown below:

Wonderware Historian 10 will be released in February 2010

Wonderware Historian 10 is expected to be generally available in February 2010. It’s going to be the first major release in few years. It will introduce a set of new features included “tier historian” – read more about what’s new here. This release will also introduce support for SQL Server 2008 (32-bit only) and Windows Server 2008.
Wonderware customers that have a valid support agreement will be eligible to receive Historian 10 license for free. Contact Wonderware PacWest if you want to get on support.

Note: Wonderware Historian 10 will only support 32-bit version of SQL Server 2008 installed as a default instance. Named instances of SQL Server 2008 are not supported.

New Wonderware Intelligence Software 1.0 introduced

Invensys Wonderware recently introduced the new Wonderware Intelligence Software 1.0.

This new, easy-to-use enterprise manufacturing intelligence (EMI) solution enables customers to contextualize, aggregate and report both historian and operational data using role-based dashboards, presenting key performance indicators (KPIs) and real-time operational business metrics that are used to monitor, tune and optimize operations and supply chains.

Wonderware Intelligence Dashboard

Wonderware Intelligence software transforms data and information from multiple sources into business intelligence by aggregating process and production data in real time and adding contextual elements, such as equipment, product, work orders, material and personnel and others.

Adding the information context enables end-users to gain insights into the root causes of problems and understand how production or process events are related to each other or the final goal. The formatted information is saved and optimized for fast reporting and analysis, allowing end users to create and publish dashboards using the Wonderware Intelligence Analytics Client into a wide variety of web portals including Wonderware Information Server. Users can also configure customized metrics without programming.

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Additionally, the solution:

  • Acquires data not only from the Wonderware family of products, including MES, InBatch and Historian, but also from external systems such as ERP, LIMS, PDM or even other execution systems and historians, to provide plant, multi-plant and corporate-wide views of operations and performance.
  • Systems such as OSIsoft PI, Oracle databases, Wonderware Historian and SQL Server databases are supported by Wonderware Intelligence’s native connectors
  • Utilizes best-in-class tools for rapidly creating and publishing dashboards that can be rendered in commonly used web platforms such as Microsoft SharePoint, mySAP Enterprise Portal and Wonderware Information Server.
  • Furthers investments in the core Wonderware products, leveraging System Platform’s Integrated Development Environment (IDE) and services for configuration and deployment of the data model and allowing customers to incrementally add MES and EMI features and functionality easily and non-invasively.
  • Is a cross-functional product, applicable to any industry or market segment

Attached screenshots show examples of various dashboards created using Wonderware Intelligence Analytics Client and published to the web-based dashboard server included with the package. Dashboards published to the web remain fully interactive.

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Wonderware Intelligence consists of the following functional components:

  • ArchestrA Integrated Development Environment (IDE) which provides development environment for creating connections to data sources, dimensions and measures
  • Data Adapters – connectors to the source data. Intelligence 1.0 provides native connectors for Wonderware Historian, Wonderware MES Operations and Performance, Oracle. It also connects to any OLE DB data source including CSV files, Excel workbooks, Access databases etc.
  • Intelligence Data Store – it’s a multi-dimensional data store (in a form of Microsoft SQL Server database) which stores pre-aggregated measures for fast retrieval
  • Intelligence Server – the server connects to the data sources and performs the ETL (Extract, Transform and Load) functions and stores pre-aggregated measures in the Data Store
  • Intelligence Web Dashboard Server – which stores published, interactive dashboards and provides them to the web clients
  • Intelligence Analytics Client – rich client tool to create dashboards and publish them to the Dashboard Server (power user tool)
  • Intelligence ArchestrA Client – light-weight client that can retrieve published dashboards

Intelligence 1.0 Server is supported on Windows Server 2003 and 2008 (both, 32-bit and 64-bit versions), Microsoft SQL Server 2008 SP1 is a supported Intelligence Data Store container. The client tools are supported on Windows XP and Windows Vista operating systems.