PM Add-ons for WinCC

Process Management System

With the proven WinCC Premium Add-ons based on the SCADA software SIMATIC WinCC, Siemens offers a modularly expandable overall solution for the optimum interaction of processes in production, quality assurance, maintenance and system integration.

Product range

Process Management Add-ons at a glance

The WinCC Competence Center in Mannheim offers a suite of premium WinCC Add-ons that further extend the powerful and scalable WinCC product family (WinCC V7, WinCC Professional, WinCC Advanced and WinCC Unified). The products provide answers for a wide range of today’s digitalization challenges and consequently focus on comprehensive and economical solutions build on standard software components.

PM-CONTROL - Recipe management and order processing

Manufacturing specifications, recipes and parameter sets are used for providing production set points in all kinds of industries and must be managed, monitored for changes in a powerful database and be clearly displayed to ensure operational quality.  Production orders are created based on these set points in order to provide plan able shop floor operation.


Either in conjunction with the PM-MES Interface, or with its integrated API, PM-CONTROL is ideally prepared for the integration with higher level MES or ERP solutions.
 

PM-CONTROL provides a flexible parameter control system for that purpose with UI components that can be seamlessly integrated into the WinCC operator screens.

Set points can be transferred to WinCC, PCS 7, WinCC Professional, WinCC Advanced, WinCC Unified and via OPC/DA. With its modular agent concept this is even possible if recipes contain set points for multiple of the above targets in combination.

The recording of recipe changes in an integrated audit trail, the support for electronic signatures and the versioning of recipes make PM-CONTROL the ideal solution in the regulated industry.

The integrated, centralized engineering library PM-LIBRARY allows the exchange and reuse of already configured components in multiple projects.

Functions like the graphical planning chart for the display of production order schedules, the rule-based checking and calculation of recipe parameters and the possibility to even create a complete custom recipe editor are consequently following the trend to provide more ease of use, overview and flexibility.

Graphical order planning chart

The planning chart control that can be easily integrated into operator screens displays the approximate processing time of all scheduled production orders over all utilized production units at a glance.
The relevant time frame can be controlled from the surrounding process screen ensuring that only the relevant planning horizon is shown. Irrelevant if that means displaying a day, a week, a month or only the next hour.

 

Rule based checking and calculation of recipe parameters

With an increasing number of required recipe parameters, the relationships and dependencies between set point can sometimes no longer be expressed with simple upper/lower limits. Sometimes multiple set points are correlated and must therefore be checked in combination. PM-CONTROL allows the definition of validation rules that e.g. the sum of a defined set of parameters may not exceed a specific threshold.

Parameter values may be calculated dependent from current values in production e.g. in order to compensate variations in specific properties of raw materials. Also influences that are originating from the production process like e.g. wear effects of tools can be already considered at the point in time when the recipe is designed.

 

Custom recipe editors

Several use cases require the display of parameter sets in a way that is more tailored towards a simplified user interface without compromising the powerful underlying functionality like e.g. versioning, audit trail and electronic signatures.

PM-CONTROL allows the creation of custom recipe editors with the standard WinCC graphical editors by providing an API set that allows the design of almost every recipe editor UI imaginable.

PM-QUALITY - Batch reporting and archiving


The acquisition, processing and archiving of batch data like trends, alarms, production set points and current values, audit trails and laboratory values as part of a comprehensive quality management system are the primary application domain of PM-QUALITY.

Based on its powerful data archiving functionality, PM-QUALITY allows the comfortable creation of appealing and comprehensive production reports for batch processes.

 

Data from various sources ranging from WinCC, PCS 7, WinCC Professional, WinCC Advanced, WinCC Unified, OPC UA or DA and even file import can be combined, archived and transformed into meaningful reports.

Whether seamlessly integrated into the WinCC operator screens or as a standalone office application, PM-QUALITY provides the required transparency.
The trends display that can also show data from several batches in comparison is combined with the overlay of additional information like alarms, event triggered readings, process phase transitions and annotations forming a powerful analysis tool with perfect usability.

Reports are always available when needed. The integrated report layout editor allows the creation of multiple different views over archived information that can be easily adapted to existing design guides.

The integrated, centralized engineering library PM-LIBRARY allows the exchange and reuse of already configured components in multiple projects.

The processing of alarms and measurements with graphical calculation rules, the support for day, week, month and shift protocols with an integrated shift calendar as well as the extended analysis capabilities provided by the seamless integration into Microsoft Excel are only a few of the additional features provided PM-QUALITY.

 

 

 

Graphical calculation rules

By using graphical calculation schemes, complex algorithms can be displayed in an easily understandable way. Calculation results can be archived in relation to a currently active batch. Statistical functions like integral, standard deviation etc. as well as more complex functions like time or state categorization are provided out of the box and can be graphically arranged and connected via drag and drop. The provided set of calculation blocks is fully extensible with custom functions due to the open system architecture.

 

 

Reporting and analytics with Microsoft Excel

With the PM-QUALITY plug-ins that are integrated into the ribbon-based UI of Microsoft Excel reports and analysis can be created more comfortable as ever before.

The first tool supports the creation of classical batch reports directly from within Microsoft Excel. Data is retrieved either from the current PM-QUALITY runtime database or from a long-term archive export database.

Furthermore, a totally new type of insight into production can be generated by the multiple batch analysis tool. E.g. it allows the extraction of specific batch readings from all batches within a configured time frame that can be further analyzed directly in the spreadsheet.

PM-ANALYZE - Analysis of Alarm and Process data

PM-ANALYZE provides a powerful archiving, analysis and reporting tool that seamlessly extends the SCADA system. 

Data from various sources ranging from WinCC, PCS 7, WinCC Professional, WinCC Advanced, WinCC Unified, OPC UA or DA and even file import can be combined, archived and transformed into meaningful reports.

With its comprehensive set of data processing functions, day, shift, week or month reports that are automatically generated are either available within the HMI screens or the PM-ANALYZE client and can also be distributed by e-mail to provide up to date information delivery.

Aggregation of measured values with several staggered aggregation levels are part of the rich feature set of PM-ANALYZE. For each aggregation level, the algorithm (like average, integral, minimum, maximum, median, percentile etc. but also complex calculation rules) and the aggregation time frame can be configured.  Subsequent modifications of values e.g. by input manual values, automatically leads to a recalculation of all dependent results.

By using graphical calculation schemes, complex algorithms can be displayed in an easily understandable way. Statistical functions like integral, standard deviation etc. as well as more complex functions like time or state categorization are provided out of the box and can be graphically arranged and connected via drag and drop. The provided set of calculation blocks is fully extensible with custom functions due to the open system architecture.

This makes the calculation of indicators like availability, performance rate, quality rate, OEE etc. easy and understandable.

Results can be used on reports, are provided in simple database API views for further processing and with the integrated charting control also displayable within the SCADA operator UI. The available charting capabilities cover various trend and bar diagrams as well as pie, pyramid, radar and funnel charts. Additionally, the visualization of machine states with the Gantt chart provides an excellent overview when comparing several equipment e.g. with respect to downtime periods.

 

Process alarms, status and operation messages from various sources contain plenty of information which sometimes only becomes visible with computer-aided analysis methods.
PM-ANALYZE does not only allow the display of messages and alarms from various sources. With its comfortable filtering and analysis capabilities it also provides an optimal overview even with large numbers of alarms. Analysis results can be directly transferred into Microsoft Excel for further processing with standard office productivity tools.
By combining and centrally archiving alarms not only from the process but also integrating other source like e.g. the Microsoft Windows event log and further arbitrary sources via text import PM-ANALYZE can reveal complex correlations.

Once mapped into a common column structure, the PM-ANALYZE alarm archives offer several analysis methods to provide valuable insights that would otherwise be undiscoverable.

Analysis capabilities:

  • The frequency analysis finds the most frequent alarms. By grouping the results freely even over multiple columns the results can be easily broken down e.g. by alarm  source. This extends the functionality of a classical top x analysis towards a more technological oriented top x analysis.

  • The flickering analysis identifies alarms that are occurring in bursts within short time frames. With this analysis methods those burst packages can be accurately spotted with an adjustable threshold.

  • The volume analysis splits the alarms in an configurable timeframe into multiple smaller sub intervals in order to locate clusters that occur in specific timeframes. E.g. a complete month can be split in single days to see if there are increased alarm counts on specific days.

Filtering:

  • Complex filters can be stored either individually for each user or globally for all users in the filter library. Saved filters can be instantly applied later on.

  • Hierarchical filters with up to 4 levels allow spotting of relevant alarms quickly and easily.  The applicable filter criterions used by PM-ANALYZE are automatically calculated from the underlying database.

  • The integrated quick search instantly reduces the displayed alarm list to matching entries

PM-MAINT - Maintenance Management System

PM-MAINT is an industry neutral maintenance management system designed to be used close to the shop floor level. By providing various connectivity options to the existing automation landscape PM-MAINT allows besides purely calendar based planning also a performance-based planning that is based on real operating hours and operation cycles.

PM-MAINT supports the maintenance process also for the recording and complete documentation of unplanned repairs by providing easy and comprehensible workflows combined with a high degree of ease of use.

Maintenance relevant information that has been calculated by PM-MAINT like e.g. recommended maintenance dates can be transferred into the existing HMI operator screens. Repair request can easily be entered directly by machine operating personal.

With its highly customizable views for e.g. planned maintenance measures, PM-MAINT provides an ideal overview which measures will become due in the upcoming timespan, thus providing an excellent planning radar.

PM-MAINT connects the maintenance with the process control level also through its well-designed client server architecture. Maintenance information such as scheduled maintenance, the intended use of tools and spare parts, necessary arrangements with external service providers, etc. are immediately available everywhere, as well as documents relevant for maintenance, such as spare parts lists or explosion drawings.

 

If required, the visualization elements of the SCADA system can be linked to the maintenance, so that it is possible to jump directly from the process control to the respective maintenance object

PM-MES Interface

The PM-MES Interface allows the seamless integration of SCADA level with MES system. It builds upon the functionality of PM-CONTROL and PM-QUALITY in order to create a standardized API level that can be used from the MES side without requiring custom scripting on the SCADA side.
The PM-MES Interface is a bi-directional communication interface between PM-CONTROL, PM-QUALITY and MES Systems. The communication is established via Microsoft SQL Server interface database.

 

 

 

This allows an MES System to e.g. create orders in PM-CONTROL, override individual parameters in PM-CONTROL on each order (variant management), retrieve batch recordings from PM-QUALITY like trends and snapshots or request the batch report generation from PM-QUALITY to retrieve the results for embedding it into the master batch record.

With this approach the intrinsic conceptual difference between the concepts on the planning side and the operational SCADA level can be standardized by using proven components instead of using custom glue logic programming.

PM-LOGON - User login via RFID

The increasing need for security has made the reliable and traceable login of authorized operating personnel for access to production facilities increasingly important.  PM-LOGON offers the operator a convenient and fast login procedure to the HMI system with the company ID card via a card reader.

 

PM-LOGON assigns the read Unique ID (UID) of the ID card to the operator and transfers this information to SIMATIC Logon, which then executes the logon procedure on the HMI system.

 

Based on its modular architecture, PM-LOGON supports a multitude of different RFID readers. Starting with the SIMATIC RF 1040R, 1060R and 1070R it also supports a steadily growing number of reading devices from other vendors in order to optimally integrate into an existing infrastructure.

 

Furthermore, in order to support a single sign on over all areas of the production, PM-LOGON is available for multiple SIMATIC HMI and SCADA systems starting from a Comfort Panel TP700, WinCC Runtime Advanced, WinCC Runtime Professional, WinCC V7 and PCS 7.

PM-OPEN EXPORT - Exporting Process data

PM-OPEN EXPORT offers a flexible and economical solution to automatically export process and archive data from SIMATIC WinCC V7 and WinCC Professional into freely designed text files (ASCII, CSV, JSON, HTML, XML, etc.).
PM-OPEN EXPORT can export to any local or shared network storage media.
 

After the configuration has been completed, PM-OPEN EXPORT runs in the background, i.e. process and archive data is transferred automatically to text files without manual intervention. Data export can be initiated cyclically, time-controlled or event-controlled. Additionally, the data export can be initiated manually at any time. A decisive advantage is the flexible and individual design of the target files. This can include, for example, static text and timestamps in addition to the exported data. PM-OPEN EXPORT is suitable for use in redundant WinCC configurations.


The following export functions are available:

  • Export of static texts and date/time stamps
  • Export of internal and external WinCC online tags
  • Export of process value archives and compressed archives from the WinCC tag logging
  • Export of user archives
  • Export of message archives from the WinCC alarm logging

PM-OPEN IMPORT - Importing process data

On SIMATIC HMI Comfort Panels or systems with WinCC RT Advanced (TIA Portal) process data (tags and messages) and operator messages are archived locally as CSV formatted logs. By using PM-OPEN IMPORT these archived data can be transferred into a central WinCC* system, where the data is safely stored in chronological order for a long time period. The original timestamps are preserved by the import. As soon as the data is imported, the standard controls can be used to display and evaluate the data.


*WinCC V7, PCS7, WinCC RT Professional (TIA-Portal)

 

Together with PM-OPEN IMPORT, SIMATIC meets the requirements for a secure, central and long-term archiving of relevant data throughout the entire automation landscape (from panels close to the machine up to a central SCADA system) as defined in the FDA regulations or in EU regulation 178/2002.

PM-OPEN IMPORT allows the import of the following data types into the WinCC System:

  • Import of WinCC Comfort / WinCC RT Advanced Data Logs
    Data from CSV-formatted Data Logs is imported into the WinCC Tag Logging or into the WinCC RT Professional Archives and can be displayed as trends or tables by using the standard controls.

  • Import of WinCC Comfort / WinCC RT Advanced Alarm Logs
    Data from CSV-formatted Alarm Logs is imported into the WinCC Alarm Logging or into the WinCC RT Professional Messages and can be displayed as tables by using the standard control.

  • Import of WinCC Comfort / WinCC RT Advanced Audit Trails
    Data form CSV-formatted Audit Logs is imported into the WinCC Alarm Logging or into the WinCC RT Professional Messages and can be displayed like WinCC operator messages in the standard control. The operator messages include the blocks “Username”, “Comment” and if applicable “Tag name”, „Old Value“ and „New value“.

PM-AGENT - Connecting multiple remote WinCC Systems to the PM-Products

PM-CONTROL, PM-QUALITY, PM-MAINT and PM-ANALYZE are all build on a common infrastructure called the PM-Server that allows the acquisition, pre-processing and distribution of all production relevant information like process alarms, process tag values etc.
This allows the extension of the installation structure from a single station system up to a centralized management infrastructure that is connected to multiple WinCC systems even when connecting to different versions at the same time.
In order to provide a unified network API for high level services where e.g. a redundant WinCC Server pair is treated as a single logical partner on the network or the buffering of local data on a remote WinCC server in case of network connection errors, the PM-AGENT is needed.

The PM-AGENT is available for WinCC V7, PCS 7, WinCC Runtime Professional and for WinCC Unified Runtime.

UNIVERSAL PM-PACKAGE - Development license package for testing and commissioning

The Universal PM Package, in combination with a supplementary agreement, provides a cost-effective way to always work with the latest versions of PM products for testing and configuration purposes and is therefore aimed exclusively at resellers of PM products and OEMs.  
The UPP consists of a USB dongle, which, together with a license file on the respective product data medium, unlocks the version of the PM product on the data medium for configuration, test and presentation purposes in all configuration variants.  
The right of use is unlimited in time, non-exclusive and not transferable to third parties.


The UPP Base package contains single licenses for the products

 

  • PM-CONTROL from V11
  • PM-QUALITY from V10
  • PM-MAINT from V10
  • PM-ANALYZE from V8
  • PM-OPEN EXPORT from V8
  • PM-OPEN IMPORT from V7
  • PM-OPEN TCP/IP from V9
  • PM-OPEN HOST/S from V8
  • PM-LOGON from V1
  • PM-OPEN MINDCONNECT from V1

in all available variants “Compact”, “Standard” or “Professional”.

COPYPROJECT - Backup of WinCC projects in Runtime

With Copy Project, a complete WinCC V7 project including all archive databases can be duplicated to a secondary storage location without leaving the runtime. Backups can be manually or automatically executed e.g. on a daily schedule and the target directories can be named dynamically in order to reflect the time when the backup was made.

PM-OPEN MINDCONNECT - Distributing production report with MindSphere cloud

PM-OPEN MINDCONNECT automatically uploads production reports that have been generated by PM-QUALITY or PM-ANALYZE in a secure way into the Siemens MindSphere cloud. In order to facilitate that, a communication channel between a virtual asset defined within MindSphere and PM-OPEN MINDCONNECT is established. This allows for a completely customizable solution where e.g. report distribution is organized by plant area, by site or other suitable criterions.

In order to access the uploaded reports from everywhere, the MindSphere application PM-REPORT BROWSER that accompanies PM-OPEN MINDCONNECT can be used.  

PM-REPORT BROWSER
PM-REPORT BROWSER gives access to reports created on site e.g. with PM-QUALITY and/or PM-ANALYZE that have been uploaded into MindSphere providing global insights into your production. Reports are available on any device capable of showing a PDF file in a standard web browser.

Key features:

  • Seamless global access to PM-QUALITY or PM-ANALYZE production reports
  • Easily scalable to multiple sites
  • Adaptive UI layout for smartphones, tablets and desktop devices

Benefits:

  • Ideal extension for existing on-site PM-QUALITY or PM-ANALYZE installations
  • Secure environment provided by MindSphere
  • Cost effective solution

Contact

Siemens AG

WinCC Competence Center Mannheim

Dynamostr. 4

68165 Mannheim

Phone: +49 621 1723-1010

E-mail: WinCCAddon.automation@siemens.com

 

References

SIMATIC SCADA solutions employing PM-Add-ons

Read how PM-Add-ons seamlessly integrate into SIMATIC SCADA systems
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