Use case 3 - Total productive maintenance
Easily sync equipment data between OSIsoft PI System, Amazon Redshift, Tableau, and Salesforce Service Cloud to resolve manufacturing equipment failures.
- High-level architecture
- Activity diagrams
- Use case considerations
- Assumptions and constraints
- Systems involved
- Processing logic
- Successful outcome
Two key manufacturing success metrics - operational efficiency and overall equipment effectiveness (OEE), directly depend on the health of the production equipment in use. Collecting, analyzing, and actioning factory floor data on an ongoing basis can be labor intensive and inefficient. This can result in either over-maintenance or worse, under-maintenance of expensive production equipment. Preventing equipment breakdowns in a capital-intensive business can have a significant impact on the bottom line.
The purpose of this solution is to leverage factory data to manage equipment maintenance in a timely and efficient manner. The solution helps manufacturing organizations deliver on their OEE goals by reducing downtime, improving capital expenditure, and avoiding accidents to make the workplace safer.
As a result, this solution streamlines maintenance of factory equipment in a manufacturing environment to result in improved overall equipment effectiveness and operational efficiency.
Use case description
This Accelerator sends data from OSIsoft PI System (a data historian that collects data from sensors, intelligent electronic devices (IEDs), distributed control systems, programmable logic controllers (PLCs), and lab instruments) to Amazon Redshift, a data warehouse product. Next, the Accelerator uses the in-built functionality in Tableau, a data visualization tool, to visualize the data. Once the equipment data is analyzed, business users can define logic in Tableau to trigger work order creation in the Service Cloud. Analyzing critical floor equipment data in near real-time improves the health of production equipment and drives overall operational efficiency.
|OSIsoft PI||Historian Database|
|Total productive maintenance (TPM)||TPM (Total Productive Maintenance) is a holistic approach to equipment maintenance that strives to achieve timely resolution of manufacturing production issues|
|Amazon Redshift||Amazon Redshift is a data warehouse product which forms part of the larger cloud-computing platform Amazon Web Services.|
|Historian Database||A service that collects real-time data streams from industrial assets, smart devices, proprietary legacy equipment–remote or mobile." and logs to a database.|
Total productive maintenance
Send shop floor data to Redshift
The diagrams below illustrate the sequence of steps to send shop floor machine data to Redshift in near real-time.
Create work order
The diagrams below illustrate the sequence of steps to create work order in Service Cloud from Tableau dashboard.
Use case considerations
- OSIsoft PI is the system of record for the shop floor machine data
- Consumers can create work orders by clicking a link on the dashboard.
This section lists the technical considerations and constraints on the solution design.
- Tableau will call experience API for work order creation and pass required values as query parameters to use Tableau inbuilt functionality to call an API
- OSI PI is a system of record for machine data
- Amazon Redshift API will use bulk operation fro inserting data into Redshift
- Tableau will use OOTB capabilities for Slack and Email integration
Assumptions and constraints
- OSIsoft PI has basic authentication enabled
- Tableau will enable a link to call experience API for case creation
- Salesforce Service Cloud
- OSIsoft PI
Shop floor Machine data is available in Amazon Redshift DB for Tableau consumption
Customers will have ability to create case in Service Cloud from logic that is entered into Tableau by a business user leveraging Tableau’s in-built alerts functionality
Customers can click on the create case link and select the conditions and create the case in the Salesforce Service Cloud.
Before you begin
|The Accelerators setup guide provides general information on getting started with the accelerator components. This includes instructions on setting up your local workstation for configuring and deploying the applications.
The processing logic below applies to total productive maintenance for a customer's shop floor. The machines keep on sending data to OSIsoft PI and OSIsoft PI keeps the data in a time series database. The process api is retrieved at a scheduled interval
The primary handling and orchestration of machine data retrieval and insert into Redshift will be implemented in the machine data process and respective system APIs.
The logic of this process for sending data to Amazon Redshift can be described as follows:
- A scheduler triggers a process API and calls the OSIsoft PI system API and retrieves the data from OSIsoft PI for a described time frame.
- The process API sends data received in the last step to Redshift system API and system API inserts the data to Amazon Redshift using bulk data insert.
The logic of creating case in ServiceCloud is described as follows:
- The customer clicks the create case/work order link on the dashboard and selects data from the drop down.
- This data from last step is sent to Tableau Case Experience API.
- Tableau Case Experience API calls the Service Cloud System API and creates the case in Service Cloud.
After successfully completing the processing, the following conditions will be met:
- Shop floor machine data is available in Amazon Redshift for Tableau consumption
- Customers can click on the create case link to create a work order in Salesforce Service Cloud
- Customers will have the ability to create alerts (email and Slack)using Tableau's in-built alerts functionality
Source type mapping
The following table summarizes how representations of a machine data from each system will be mapped to machine data types.
|Source System||Object Type||Target Types||Mapping Notes|
|OSIsoft PI||Machine Data||Machine_ID |
Measured_Value - e.g. 80, 1.88
Measured_Unit - e.g. Fahrenheit Hertz
Source - e.g. OSI-PI, IoT etc
Target type mapping
The following table summarizes how representations of a machine data from each system will be mapped from machine data.
|Target System||object Type||Target Types||Mapping Notes|
|Amazon Redshift||Machine Data||Machine_ID|
Measured_Value - e.g. 80, 1.88
Measured_Unit - e.g. Fahrenheit, Hertz
Source - e.g. OSI-PI, IoT etc
- MFG OSIPI Machine Data System API | API Specification | Implementation Template
- MFG Redshift Machine Data System API | API Specification | Implementation Template
- MFG Salesforce Cases System API | API Specification | Implementation Template