Orbis Enterprise Manufacturing Intelligence (EMI)Orbis EMI provides breweries with the means to control and minimize costs while improving customer service by reducing energy and environmental costs, minimizing beer losses and maximizing process capability. EMI provides proactive performance management based on a "Perfect Plant-Brewing" performance model. Analysis tools include KPI Scorecard, Track & Trace, Quality Monitor, Stocks Monitor, Mass Balance, OEE Monitor and Utilities Monitor.
The KPI module comprises a configuration wizard, a scheduler, a calculation engine and a GUI consisting of a balanced scorecard and performance monitor. The KPI module is configured by generating KPD's using a configuration wizard. These KPD's are typically created on a batch or time basis by using algebraic expressions against KOP's. The results are stored in the Performance Database and the scheduler is configured to execute the calculation on either a time or event basis.
KPD's are in turn weighted and consolidated to generate KPI's which can then be reported and analysed using the Performance Scorecard.
The scorecard is the primary interface for analysing configured KPI's in the performance database. These represent the base level of performance metrics. These KPI's are in turn rolled up in the OLAP CUBE according to a predefined model. The Performance Monitor then provides a rich user interface for multidimensional analysis of the CUBE and associated KPI's.
OEE Overall Equipment Efficiency
The OEE module generates overall equipment efficiency and utilization for key assets and plant. The OEE module comprises a scheduler, calculation engine and web based reporting tool.
The OEE module monitors the utilization and performance of key equipment particularly bottlenecks and key assets in the production process. The standard rules as defined by OMAC are built in to the calculations.The OEE data is generated on an hourly basis and includes total Utilization, Available utilization and productive utilization as well as Availability, Performance, Quality and OEE. The OEE monitor is the GUI which allows Utilization and Performance metrics to be displayed and analyzed.
Track & Trace
The track & trace module provides equipment based traceability and genealogy for all batches within the brewery.
Transfer and production batches are recorded in the Production Database using the Batch Extractor engine against the PCS system. Within the Production database the linkages between batches, equipment and transfers are established and maintained. The Track & Trace GUI is then used to mine and display genealogy using a tree paradigm.
Quality and Stocks Monitor
The integrated stocks and quality module provides a vessel based view of actual stocks and work in progress. Stock locations are configured in the IQS module, these locations are updated with production and transfer batches from the production database so that at any given time it is possible to view the location and see what product is available, its quality status, the stage in the brewing process and the associated vessels.
The Mass Balance module provides reconciliation of the constituent materials in a raw material before and after a stage in the process.
It is configured for each brewing process and it maintains a reconciliation of all raw materials into the process stage and finished product out of the stage identifying yield and losses.
Utilities MonitorThe Utilities Module measures utilities consumption and demand for predefined cost centers.
It comprises a configuration wizard for setting up cost centers, a calculation engine, a dedicated database and a graphical user interface.
The Utilities Monitor allows usage and demand to be displayed, analyzed and reported for a given cost center over a predefined time period.
Quality MonitorThe Quality Module allows in process qc results to be logged against a batch depending on the stage in the production process.
It also allows results from LIMS to be extracted. The Quality Monitor provides a GUI which allows quality results to be viewed analyzed and reported.
EMI Site Portal
The site portal provides a personalized user environment whereby each of the preceding modules can be accessed using customized dashboards.
The Dashboards can be customized using web parts so that a user only sees the information or analysis tools that are of relevance to his role. It is envisaged that the following user groups will be configured Operator, Supervisor, and Administrator. Each User will have a user name and password which are linked to the Active Directory. Audit trailing allows user login and user activity to be recorded against that user.