Information-2-Intelligence

Process understanding is only a few clicks away
We are proud to offer the i2i Manufacturing Information Management & “DataVis” Platform
transforming Information-2-Intelligence at the speed of “Click”

Introducing a breakthrough in Business Intelligence and Data Visualization for the
Manufacturing Environment: Information – to – Intelligence (i2i)
These days it’s all about speed – the advent of the Internet coupled with a high-speed connected society has
completely transformed the way all of us want [and need] to interact with the data we use to increase our
productivity: Not only do we want information right away, but we demand it on our terms as well – and we
couldn’t agree more. With over 20 years Manufacturing Engineering and Integration experience we’ve answered
the Information Management needs of our customers with a data management solution that can be deployed
Authorized Partner Integrator
and validated quickly to provide the entire organization with access to the critical data they need – now and on
their own terms. See for yourself by scheduling an on-line test drive of a complete i2i solution.

copyright © 2009 exoCite Manufacturing Solutions, Inc.

Bringing over 15 Years Process & Industrial Control Expertise to the Enterprise
Specializing in building Industrial Automation Systems from the Plant-floor to the Enterprise
our engineers have built a solid reputation for delivering World-Class Manufacturing Solutions

Authorized Partner Integrator

The key to a successful Enterprise Data Solution is to Simplify your Architecture
Reducing discrete data stores to a well-designed Relational Database and Plant-wide Historian Architecture
will ease deployment and validation efforts and increase project success rates substantially
– at a significantly reduced Total Cost of Ownership (TCO)

Plant
Batch
RDBMS
Plant
PAT
OEE & Other “Results”
Efficiency Data
Data
Plant
Historians
Plant or (Primary /
Corporate Redundant)
Domain
Manufacturing
& Packaging
Areas
PAT Spectral
Raw Materials
Data
&
LAB & QC
Data


A Single Interface designed for a Multi-Purpose World
Leverage the power of the RDBMS to satisfy the data requirements of those who need it most

Technology Group & Regulatory Quality Control & Quality Assurance Group/
Reporting Laboratory
•
• Manufacturing Investigations
Batch and Product Investigations
•
• Recipe Configuration Verification
Recipe Editing & Tracking configurations to production
•
• Raw Materials Usage Reports
Batch-to-Batch Compare Facility
•
• Alarm History by Batch
Process trends by Batch
•
• Extended Batch & Production Reports
Alarms & Events by Batch
•
• Process Risk Reports for Product Release
Raw Materials Usage Reports
•
• Regulatory Compliance Reporting
PAT & Human Sample Data

Manufacturing & Packaging Groups Corporate Management, IS & Efficiency Systems
•
• Alarm & Batch Frequency Reports
Real-Time Process Trends
•
• Production Down-Time & OEE Reports
Recipe Configuration Usage
•
• SIX Sigma/Batch Statistical Information
Work Instructions & 21CFR Part 11 Electronic Signatures
•
• Batch and Production Cost Analysis
Audit Trails by Date & by Batch
•
• Human Resource & Training Tracking
Alarm & Batch Frequency Reports
•
• Headcount Planning
Batch & Production Reports
•
• System Performance Reports
Equipment Down-time & OEE Reports
• Regulatory Reporting

Maintenance & Engineering Group Materials, Inventory & Resource Planning
• Real-Time Process Trends for PID and Process Tuning • Batch & Production Reports
• Alarm Histories & Alarm Frequency Reports • Production Down-Time Information
• Preventative Maintenance (PM) Reports (by Time / Usage) • Raw Materials usage Reports
• Recipe Configuration tracking to production • Batch Frequency Reports by Product
• 21CFR Part 11 Audit Trails & Audit Histories • Raw Materials Genealogy
• Alarm Frequency Reports (Occurrence, Time-to-Resolve) • Annual Summary Reports
• Batch Frequency Reports (Batch & Step Time-to-Complete) • Monthly Equipment Utilization Reports
• Historical Trends by Time/Date
• Batch-to-Batch Compare Facility


Process Improvements through modern Data Management and Information Layering
Combining traditional Historian Data with a rich S88 compliant Manufacturing Data Model

Comparing a known good “Golden Master” batch against another batch
Q: How do our customers utilize a comprehensive manufacturing
relational data model coupled with visualization and reporting tools
to better understand their processes? A: Through Data Layering
from many data sources tied together through our highly intuitive
visualization tools. The image on the left demonstrates our powerful
and highly intuitive batch comparison tools. The image below
combines traditional process historian data with many other pieces of
information related to each particular batch including Alarms & Audit
Trail Events, S88 Recipe Configurations, product details, process
steps, and logged-in operator information.

Don’t just view data, interact with it
The latest industry and regulatory agency trends call for improving
process understanding through the use of innovative technologies.
But to improve our processes requires that we do more than simply
view the copious amounts of raw data produced by today’s modern,
complex manufacturing processes. Other industries are moving
towards interactive data management & visualization tools
(“DataVis”) and applications, yet this technology is still largely out of
reach in the world of real-time manufacturing systems – that is until
now. Through the use of a powerful S88/S95 Manufacturing
Relational Data Model coupled to highly interactive “data layering”
visualization tools, our customers are able to know and understand
S88 Recipe Data Model, Batches & Steps, Alarms & Events & Historical Trends
their processes faster than was ever before possible.


Use the power of the rich data model to make sense of your historical process data
View S88 Recipe Configurations, 21CFR Audit Trails, Alarm Histories and Batch Data at a glance


From a good data model springs practically unlimited Reporting opportunities
Move beyond simple batch reporting to produce rich process optimization and efficiency reports


Data may come from many sources, but now one tool can make sense of it all
Combining traditional Historian Data with a rich Manufacturing Data model
Combine Alarm History information with Historical Trends
to demonstrate relationship between those events

21CFR Part 11 Audit Trails combined with Trends
demonstrates direct relationship of user activities

S88 Recipe Configuration Data per process step situated adjacent to Historical Trends – Helps demonstrate the effectiveness of each recipe revision


Quickly visualize the differences between large numbers of batches
Summarize large quantities of data using powerful built-in Charts and Graphs tailored to each process

Q: How do our customers quickly scan many batches to find
the ones with the greatest potential risk? A: Through the use
built-in charts and graphs to visually pinpoint areas of interest
within the data. Once identified, users can switch to the
process compare utilities to quickly perform “Golden Master”
comparison studies. The image below demonstrates a chart
that is currently used to determine which coating batches
required extra shots of solution. This report was previously
created by hand through a labor-intensive data entry
procedure using Microsoft Excel, but was easily and quickly re-
produced using the data available in the RDBMS.

The image above is an example of two separate coating
batches from the same coating pan: one that required
several additional final coating steps to complete and
another that executed normally (the “Golden Master’).
Viewing the batches side-by-side and combining Audit Trail
Event data with the Historical Trends, investigators were able
to quickly identify the root cause of the problem batch and
implement changes to critical procedures to reduce future
occurrences saving valuable time, materials and potentially
lost batches.


Process Understanding through effective data management techniques
Combining traditional Historian Data with a rich Manufacturing Data model
Comparing and entire batch against another – good for getting the whole picture in a single mouse click
Q: How can our customers leverage their investment in
existing plant historians to improve process understanding?
A: By combining RDBMS batch information with the Plant
Historian Process Data to produce unprecedented navigation
and data layering capabilities. Historians offer highly
configurable views of process data that cannot be easily
attained with an RDBMS alone, so it was a natural fit to
combine the information from these very distinct and rich
data stores.

The example above illustrates traditional process data
obtained directly from the plant’s existing historian database.
Process Alarms, Audit Trails, S88 Recipes, Process Steps, User
Information, batch and step times, etc. are retrieved from
the RDBMS and overlaid directly on top of the historian data
to create a level of detail that could not be achieved in any
other way. The example on the right demonstrates batch
comparisons using RDBMS data only. In this case process
data is sent to the relational database during batch
operations as well as continuously to the plant historian
providing an extra layer of protection against data loss.

Comparing Individual Process Steps between multiple batches


Retrieving your process data by time is fine, but why not navigate by batch as well?
The S88 data model does far more than just store data – it can also help you to navigate through it

Retrieve critical batch data directly from RDBMS Retrieve data directly from your Plant Historian (Proficy Historian, OSI PI, Aspen, etc)

Coating information
(from Historian)

PAT Datasource

Granulation and
Drying Process
(from RDBMS)

then – Combine data from multiple data sources including relational databases, PAT data sources, Building Management Systems (BMS) & Environmental and Plant Historians

Use the Data Model for what it was originally designed to do, summarize data
Direct your efforts using rich charting tools specifically designed to identify costly process problems

Q: How do our customers determine if their batches are
running consistently over time? And how can we quickly
convey which areas need immediate attention to keep each
process running smoothly? A: We continually strive to
identify new ways to present batch and process data to users
that quickly lead them to problem areas that will reduce
process efficiencies and cause down-time and lost batches.
Effective charts and graphs can very quickly convey a great
deal of information in a very small amount of space

The example above demonstrates the amount of time
each batch and process step took to complete. Extended
batch or step times time can be an indicator of process or
equipment problems or even operator error. A reduction
in batch or step times can also be an indicator of potential
product quality issues and may warrant additional
investigation during the product release process. The
chart at right shows which alarms occurred most often
and which ones took the longest to resolve. Those that
took longest to resolve and/or occurred most often would
indicate a good place to make process improvements to
reduce costs and improve process efficiency.


Fully integrated Adobe® Acrobat™ Reader enables organization-wide collaboration
Share critical manufacturing data using Adobe PDF file format. Enable full-text searches of any report
Built-In Adobe ® PDF Viewer provides extensive Report Searching Capabilities

Integrated Adobe® Acrobat™ PDF Reader
The power of the built-in Adobe PDF (Portable Document Format) reader makes saving and sharing reports
a very simple process. The PDF reader plug-in also includes extensive full-text search capabilities that eases
the batch investigation process by quickly locating key information in large Alarm & Audit Trail Histories
and Production and Batch reports. Searching a batch report (above) for “Inlet” reveals every Inlet
parameter entry including both “Airflow” and “Temperature”. This feature is often used to determine if all
procedures were faithfully followed during each phase of the batch process. The days of manually pouring
Quickly Build any
report by Date over hundreds of pages of batch and production report data to find a specific piece of critical information
Range or by Batch are finally coming to an end.
Number

Bring i2i to the plant-floor by integrating with any modern SCADA/HMI Application
Integrate our powerful Data Visualization tools on the plant-floor to improve any Manufacturing Process

Actual Production GE Proficy SCADA/HMI Software with i2i Visualization Tool Integration

21CFR Part 11 Compliant Electronic Signatures

S88 Recipe Integration


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