Te c h n o l o g y a n d S o l u t i o n s f o r P l a n t I n t e l l i g e n c e .

Integrates plant floor with your business

Te c h n o l o g y a n d S o l u t i o n s f o r P l a n t I n t e l l i g e n c e .

“Having production data

at your complete disposal
in realtime means being
able to recognize
and anticipate weak points
in production systems,
make bottom-line decisions
with confidence to increase
productivity and efficiency.”

Manufacturing • Food & Beverage • Chemical • Pharmaceutical • Utilities • Energy • Oil & Gas • Packaging

2
 Integrates plant floor with your business

Guaranteeing production process A ‘must have’ for any manufacturing

Production data information flow in realtime, enterprise company. MovTracer © comes with a
wide, from shop floor sensors directly to suite of historian modules which can be
acquisition the company managerial offices, is the selected and used for collecting data,
true solution for improving productivity and where key indicators (KPI, OEE)
in realtime and efficiency, reducing loses and increasing can be represented in displays using
profits. In fact, the ideal production lies an “Analyst Web-based” component
monitoring main on the real factory machine capabilities to analyse data and production
of working non-stop at maximum speed, “dashboards”. Thanks to the MovTracer ©
performances without downtimes or inactivity and solution, manufacturing companies
product reject threats. Today staying can truly discover the real productive
(KPI) allow you to market competitive is paramount but capacity of their enterprise systems,
unsustainable if you don’t use the right machines and production lines, easily
make productivity technology. pin-point criticalities and imperfections
Production lines will be prone to and get the right information needed
improvements, standstills and will produce defective to improve efficiency. Enhancing
pieces if the machines are unable to work performances to become more
reduce loses and at their full capacity or meet demands efficient will improve productivity,
made of them. This is often the case of add more value to production system
increase profits. misinformed factory management on activity, reduce investment recovery
realtime factory floor performances. times and re-enforce company
Even though equipped with OEE indicator competitiveness. Globalization today
knowledge, they still do not have means manufacturing companies cannot
systems that run efficiently to provide risk being slack and non-competitive
productivity improvement. This is where if they want to survive. Staying
MovTracer©11 steps in, the most simple competitive, strategic steps must be
and affordable solution to manage and taken to reduce production costs by
aggregate information flowing directly improving production machine use
from production lines straight into the and flexibility to manufacture top
hands of company managers, laid out in quality goods. MovTracer © has been
the plainest and simplest way ever. An created just for this by offering cost
essential aid to close that gap between contained tools designed for collecting
shop floor productivity, managerial offices realtime information flowing from
and improve enterprise-wide resource manufacturing points, connecting
planning. Based on years of tried and company IT tools (ERP, SAP) directly
tested Industrial Connection and Data to production lines and analysing
Collection technology experience, Progea coefficient productivity processes using
have come up with the best solution for tables and charts in an integrated
plant floor and business integration with and open architecture through web
the MovTracer© platform. access-based solutions.

3
Te c h n o l o g y a n d S o l u t i o n s f o r P l a n t I n t e l l i g e n c e .

Plant Intelligence solutions

to improve productivity.
MovTracer © is the best solution for SAP™, AS400™, etc.). Furthermore,
The most innovative supporting decision-making processes. purposely-designed ODBC connectors
Thanks to MovTracer © you can measure consent bidirectional connections
and open software performances in realtime, by collecting with different managerial systems,
and aggregating production process permitting you to create MES solutions
technologies data deriving from different sources at with ease, such as managing or
factory floor level (PLC, HMI, SCADA) launching orders or production batches
to safeguard your and analyse realtime situations with or synchronizing and coordinating
all relevant data showing general processes and resources. MovTracer ©
investment. production indications, independently also includes powerful report tools
from the original data source. for processing recorded data and
Production managers can rely and react producing analyses and statistics,
on this information to determine the all freely configurable locally or in
best measures to take and put them distributed architectures. The KPI
into effect immediately to improve and OEE modules can be used to
performances. MovTracer © offers safe get the main productivity indicator
and efficient connectivity tools, capable representations in accordance with
of collecting information directly from the standard requirements, which
its point of origin. Information can nevertheless are always customizable.
be aggregated and calculated using The KPI and OEE indicators can be
the pertinent configurations and visualized in web architecture using
control logic. Data can be recorded on normal internet browsers. Progea’s
relational databases using a powerful company policies are clearly evident in
high performing ODBC Manager that the MovTracer © solution to guarantee
works independently no matter what simple, open and reliable solutions
historical log format therefore easily based on the best software
adaptable to any client standard technologies around today.
(i.e. SQL Server™, Oracle™, MySQL™,

4
Flexible and open architecture.

Thanks to MovTracer©, you can insert PLCs, CNCs, Remote I/Os directly, and Server, ORACLE, MySQL). OEE and KPI
your MES system directly into your consents connectivity via OPC Client or performance indicators can be displayed
business by connecting it to your Server towards HMI or production line locally or by remote control thanks to
production lines without having to worry pre-installed SCADA systems. Therefore MovTracer’s© web architecture. This
about which connection modalities data can be collected without effecting system also consents full bidirectional
to use. MovTracer© actually provides investments and without the need for connectivity with ERP or SAP systems for
you with various integrated solutions additional installations on the production total information flow control throughout
which consent connectivity towards side. Data is then aggregated and the shop floor to the director’s office, a
production process systems through stored on Relational DB tables tailored complete enterprise-wide coverage.
I/O drivers designed for connecting to your needs and preferences (i.e. SQL

5
Te c h n o l o g y a n d S o l u t i o n s f o r P l a n t I n t e l l i g e n c e .

Real-time information to find and remove

inefficiencies to improve productivity.
Thanks to the KPI indicators (OEE and Reduce Machine downtimes
MovTracer Downtimes) calculated on production With the help of analysing machine
data collected by MovTracer ©, your stoppages, you can eliminate
will make your company can maximize productivity foreseeable, repetitive problems
by increasing production in the three causing them. This will reduce shop
machines work more main areas relating to Availability, floor downtimes amounting to a
Performances and Quality parameters. significant reduction in management
efficiently thanks to key costs allowing you to reorganize human
Increase Efficiency resources more productively.
performance indicator Thanks to local and global production
efficiency improvement, you can now Increase Production
analysis allowing you to exploit the capacity of your existing By increasing efficiency and reducing
machine productivity, reduce scrap, production inactivity, will increase the
reduce losses and improve efficiency, enabling you to cut real capacity potential of your shop
down on management costs and bring floor production lines.
increase profits. production plans to term successfully
and deliver on time without requiring Improve Quality
extra staff. Thanks to the production data and
scrap production analysis, you can easily
track down the causes for production
defects, remove them to increase
production quality that will definitely
satisfy customers.

6
 Connectivity
at all levels.
The Real-Time
database offers
integrated
I/O Drivers,
DB connectors and
‘par excellance’
networking for
enterprise-wide
communication.

Fast and safe communication is essential The integrated Networking consents

for enabling the MES system to get all transparent data exchanging, native
the necessary data instantly whenever between other MovTracer © stations
and from wherever needed. MovTracer © connected in Ethernet networks, or with
represents a process data gathering other stations and WinCE HMI panels
point, the crossroads of enterprise-wide using Movicon™ Scada/HMI.
production system information flow
at full scale. The strategic role of Connectors DB e OPC
communication is paramount MovTracer © also offers special DB
in MovTracer ©, integrated with connectors which can be activated in
all the necessary tools to make read and write in any variable, to allow
information flow easier, faster data exchanging between the real-time
and more transparent. MovTracer © database and any other business
integrates a rich library of I/O Drivers, enterprise application or system using
native, integrated and included simple shared tables. This system is
free-of-charge in the product, to render also predisposed with the option to
communications with various control customize data exchanging with third
systems completely quicker to configure party applications, made possible by the
and perform. Furthermore, special data access driver to shared memories
wizards help you configure and import (Shared Memory I/O). The Real-Time
project variables directly from the PLC database therefore permits you to
automatically quicker with fewer errors connect to any existing shop floor level
than ever before. The I/O Driver library control device (back office) to collect
supports all well known PLCs and and disclose information to higher
systems, and can be expanded to third enterprise-wide levels (front office)
parties using SDKs. The OPC technology in realtime.
is completely integrated both as Client
and Server, covering both the DA (COM)
and XML DA specifications.

7
Te c h n o l o g y a n d S o l u t i o n s f o r P l a n t I n t e l l i g e n c e .

Data Collection
with forever
safe data.
Process data
archivable in any
relational database,
or in encrypted
format.

All process data collected by as well as maximum openness in analysts to manipulate as required.
MovTracer © is recorded and stored for choosing preferred database formats. MovTracer © can therefore perform
analysing using freely-configurable MovTracer © supports all relational DBs tasks that are usually done by
and purposely-designed Data via ODBC or in simple formatted and Historian systems for collecting
Logger objects. This information encryptable text files to obtain the and recording data on database. In
collection guarantees production visualization of recorded information addition to the Data Loggers, users
managers with all process related exclusively through the MovTracer © can freely configure event records
information with the possibility to access control modalities being with associable text (i.e. Alarms or
analyse data to improve productivity, totally compliant to CFR21 Part11 Messages) or record on Audit Trail
by tracking down and isolating requirements. events. Thanks to the powerful ODBC
anomalous behaviour. The MovTracer © Manager, databases can now be in
configurator enables you to aggregate Data Loggers, Tracing and Log whatever format preferred
data with great ease and define The Data Loggers record process data (i.e. SQL Server, Oracle, MySQL),
archive recording and management with ease and speed. Recording on DB guaranteeing maximum openness
modalities. This important task is tables can be set to occur according and adaptation to already existing
performed to guarantee concepts to time frequency ranges, on event or company systems, reducing costs with
based on simplicity, reliability and variation (also with dead band). fast return on investments.
openness. MovTracer © offers recording Thanks to a simple object-oriented
engines based on a ODBC Manager configuration, realtime data can be
model which ensures maximum aggregated within database tables
performances in data precision and made available to Data Center

8
Redundant data functions and much more without Report Designer™
MovTracer © can be applied to “Mission having to fork out more on additional MovTracer © also has a Report Designer,
Critical” data acquisition systems by and often rather expensive tools. which is a powerful integrated
offering the option to manage data The reporting solutions available in Report Generator based on the
Redundancy functions, consenting MovTracer © are: .Net technology to allow powerful
historical data synchronization in PC reports to be created visually with
systems with redundant hardware and Crystal Report™ statistical and graphical functions.
communications. MovTracer© integrates the Crystal This integrated feature will further
Report© the Report Engine, a powerful save the user time and money as
Integrable Reports Business object dedicated to producing external tools, like Crystal Report, are
The MovTracer © Data Loggers integrate professional and powerful reports. no longer necessary. MovTracer Users
unparalleled potentiality into Data Thanks to this integrated report engine, can now opt to use the integrated
Collection systems: in the form of users can now manipulate the Crystal reporting tools provided to create
powerful inbuilt Report management. Report Designer (.RPT) to insert report reports within the same project with
Thanks to MovTracer © , historically files, created with the Designer, in the less hassle.
logged data can now be visualized MovTracer Data Loggers to then be
in analytical and statistical reports, connected to for visualizing or printing
which can be created and customized production data according to the
directly in the data collection system. modalities set in the custom presentations
This powerful feature permits you to and calculations.
perform local and custom analysis of Thanks to the VBA scripting, reports
collected data in order to view total can be managed, visualized and
amounts, averages, reports, statistic customized to specific user needs.

9
Te c h n o l o g y a n d S o l u t i o n s f o r P l a n t I n t e l l i g e n c e .

Integrated Languages and functions.

Object-oriented programming Logic Language

Script VBA™ alone is not often enough to fulfill MovTracer © also integrates another
complex tasks and out-of-the-norm type of language, the IL Logic. This
and IL Logic offer requirements. It is fast becoming more language is a combinatory language
dispensable to aggregate and calculate common to PLCs (Instruction Lists or
powerful logic collected data, or execute algorithms, or AWL). A powerful instruction set allows
functions for custom aggregation and logic and calculations to be managed
functions for interpretation of collected data before with basic PLC programmer know-how,
recording it on DB tables. Whatever without the programmer needing VBA
data collection the requirement, it can be successfully language experience.
realized using the powerful integrated
calculations and language tools which offer unmatched Schedulers
solutions. MovTracer © integrates scheduler objects,
aggregation. capable of executing scripts and
VBA Language functions based on preset times and
MovTracer © integrates a powerful VBA dates or cyclic conditions.
engine, capable of executing code
perfectly with VBA standard (Visual Event Objects
Basic for Application™) compatibility MovTracer © integrates Event objects,
along with the use of a truly powerful capable of executing scripts and
and wide-ranging API set. The VBA functions based on logic conditions
scripts, which support multithreading determined by associated variables.
and .NET syntax, can be executed
directly at startup or on specific events
linked to variable status conditions. In
addition, the powerful debugger offers
the option to perform step-by-step
operations or break-points.

10
Access your business information whenever
and wherever through the web.
Every manufactoring company fully Open and flexible OEE Modules
The main objective knows the importance of having the for “Plant Intelligence”
right facilities that let them access The Analysis modules included with
for collecting factory information in realtime from MovTracer © are based on web technology
anywhere and at anytime. Progea has and are equipped with completely open
production data developed MovTracer © front-ends, an and customizable solutions to fully meet
innovative software solution based on any type of need covering a wide range
is to obtain the most modern ASP.NET technologies of specific production methodologies.
for collecting business information at The locally installed MovTracer © modules,
OEE indicator a enterprise-wide level, covering the are based on the ASP.NET technology
entire shop floor right across to the and consent the use of the Windows
measures and make managerial offices, in realtime through Web Server (IIS) so that users can
an Internet or Intranet architecture. visualize all the statistical information
information available Thanks to MovTracer © front-end needed in real time from any Client
technology you can visualize KPI terminal through the company’s local
to factory managers performance indicators of your business network or over the internet.
using a simple browser, allowing you The modules are open to customization
through the web. to drastically reduce management, and equipped with the appropriate
maintenance and license costs that Licensing formulas tailored to reduce
no other MES system available to implementation costs drastically
day can guarantee, keeping company and provide maximum freedom to
investments to the minimum. customize, thanks to the most popular
and widespread used technologies
and standards. In addition to these
modules, the system has been designed
to guarantee accessibility to recorded
data using custom solutions or DB
Connectors for reading/writing data
towards other managerial systems.

11
Te c h n o l o g y a n d S o l u t i o n s f o r P l a n t I n t e l l i g e n c e .

OEE Module 2.Performance -The percentage of

pieces actually produced compared to
be able to discover the weak points and
production downtime causes and take
The OEE indicators are recognized as the
the planned amount. action to correct and reduce further
main and most effective indicators for
3.Quality-The percentage of defective losses. By retrieving just 2% of production
measuring global shop floor efficiency.
pieces compared to the total pieces losses will gain the company 3.5 hours of
The principle use of OEE is to maximize
produced. productivity a week, totaling 168 hours
marketable products by increasing
These indicators are obtainable by more productivity a year. This small 2%
productivity in the three main areas:
applying specific filters based on different production recovery alone will make a
availability, performance and quality.
time ranges, production lines and substantial impact on profit increase.
Thanks to archiving production data
machines, Shifts, Batches and Workers. Today, based on a challenging OEE value
in realtime and relative OEE analysis,
of 100%, the most efficient companies
manufacturing company business
OEE = Availability * Performance * Quality with major productivity usually benchmark
managers can now understand
and reach an OEE target value of 80-85%.
production performances much better
This essential information consents factory Most companies that do not implement
and identify those areas which are
managers to improve production assets, any productivity control only operate at an
lacking in efficiency. The OEE provides
machine efficiency, optimize times and average of 60-70% of their real capacity.
a very clear picture on how things
reduces any wasted. A company registering It is clearly in the best interests of any
are going on the efficiency side of
a very low OEE value will be constrained manufacturing company to fully consider
production by showing measured
to increase its unitary production costs the great advantages offered by these OEE
rates and qualities with an overall
and therefore may jeopardize profit gains indicators to help reduce loss and make
performance total.
and business opportunities. For example, profit gains.
The OEE manufacturing unit performance
a production line running 24/7 will loose
measurements are based on three factors:
the company 4% productivity for each
1.Availability-The percentage of actual
hour of downtime a day. By being able to
operating time, known as Uptime,
analyse production data, the company will
compared to the one planned.

12
 shop floor staff breaks or meetings and so operator and more. The graphical charts
DownTime Module forth) and these must be found out with and graphs can be displayed and printed
However, the OEE indicators alone are not the full and essential collaboration of all as historgrams or overlapping statistical
enough to pinpoint the exact shop floor staff. MovTracer© has just the curves. In addition to statistical calculations
causes of inefficiency. It is essential that right modules for analysing these types of and graphical representations, the system
the data collection system be capable DownTime causes. Statistical analysis on permits users to create summaries on all
of providing the right information production downtimes can be produced filtered data in detailed reports.
needed for discovering such causes according to the possible motivations
(or macro causes) of productivity (configurable). This analysis will provide,
loss and performance inefficiencies. production managers with all the vital Trend Module
This information is fundamental to information ever needed to make the right The Trend Module is a straight forward
ascertaining the inefficiency causes decisions and implement the right actions simple approach to give users better focus
so they can be removed. Receiving for correcting errors to improve production on their production behaviour. Users just
notifications of alarm occurrences, management. simply select the desired values recorded
generated automatically by the system, by the system and use the Trend curves to
usually do not contain sufficient Statistical Analysis represent their behaviour throughout the
information. The DownTime analysis module permits selected time ranges which then can be
Not just production line machinery you to statistically visualize data relating displayed, exported or printed as pleased.
but everything else on the shop floor to downtimes and show them in different
should be submitted to full inspection. classifications graphically in order of Total
There may be various reasons causing Duration or Intervention Frequency, to
production downtimes (i.e. shift or report values retrieved from historical
machinery component changes, missing logs and represent them clearly in graphs
raw material, machines being serviced due and charts using various filter methods
to scheduled maintenance or breakdown, which include; time range, batch, shift,

13
Te c h n o l o g y a n d S o l u t i o n s f o r P l a n t I n t e l l i g e n c e .

Look confidently to the future

with our valued added Support and Services.
Progea, through its network of Partners, of the entire project from beginning to end. your productive system is performing.
Solution Providers and System Integrators, Any company using the Progea products can This indicator alone cannot improve
are experts in providing their end clients rest assured that they are in the right hands. productivity without being combined
with all the support and services necessary Progea is completely competent in assisting with the cooperation and willingness
and fundamental to any project success. their clients in analysing specific needs, of all enterprise-wide levels working in
There are many advantages to be had in putting them into the right prospective and unison, which means from shop floor right
using a standard product, but setting up the implementing them on a tried and tested through to the business management
project, tailoring it to specifications of each basis until fully validated and working to offices. Working together to remove the
manufacturing company needs requires skill client’s satisfaction. The OEE (for a machine, OEE indicated causes that are jeopardizing
and expert know-how which play crucial roles, production line or entire factory) only gives company productivity is the only way to
if not the main roles, in guaranteeing success you an indication on how bad or how good complete success and a secure future.

Progea has been in operation since

1990 producing software platforms for
industrial automation. A long tradition
attesting Progea’s matured experience in
this sector is based on a strong vocation
for innovation boosted by a young,
reliable and enthusiastic team working
together in harmony. Progea’s top priority
is quality: the company is ISO 9001:2000
certified and their software products
undergo strict testing with certification
based on the required standards. Their
services are provided by a motivated and
competent team, fully focused on specific
client needs, providing great satisfaction
proven by numerous partner references
which include Phoenix Contact, Panasonic,
Asem, Vipa, Suetron and many more.

14
Main
Features.
Openness. MovTracer© is completely Powerful Data Logging. Collected data Open and Custom KPI analysis Modules
based on XML. Collected data is handled can be recorded using Data Logger object The KPI analysis modules propose simple
by powerful ODBC Mangers to guarantee oriented configurations, which can be and effective solution for obtaining OEE
preferred formats in Relational DBs. The connected to DBs in different formats. and Downtime indexes with a straight
Front End technology is based on ASP. Data can be recorded according to preset forward, quick and open approach.
NET. times, on event or change. The Tracing Reports, Tables and graphs permit
(Audit) feature is also supported for complete and thorough production
Security. MovTracer© guarantees recorded data and Alarm events. analysing, with the option to print and
maximum data security which can be export them as desired.
encrypted with 128 bit algorithms. The Connectivity. MovTracer© introduces
FDA CFR21 Part 11 specifications are a new generation of communication Integrated Connectivity
supported in the data collection system. drivers. These drivers include with Movicon™.
functionalities such as automatic Tag In addition to interfacing with any
Standards. MovTracer© is completely importing, remote connectivity via supervisory system, MovTracer© also
based on standard technology to modem, multi-station concept for offers users the great advantage of
safeguard your investment. The XML, point-to-point protocols. They also having network connectivity with the
ODBC, OPC, VBA, Web Services, TCP-IP guarantee full configurability and the Movicon Scada systems and with WinCE
and SQL and Crystal Report technologies option to communicate on event in HMI panels based on Movicon CE.
are integrated in the platform to custom mode using VBA logic as well.
guarantee easy access and data In addition to the free included drivers
transparency. library, MovTracer© offers full connectivity
via OPC, using OPC DA and OPC XML DA
Performances. MovTracer© increases technologies, for both Client and Server.
performances thanks to its renewed
“exception-based” technology concept Custom Reports. MovTracer© integrates
together with the powerful ODBC a Report Designer to allow users to create
manager which consents data collections powerful custom reports locally, which
up to a frequency of 10 m s. can be associated to the project’s Data
Loggers.

15
 MovTracer™ is a Progea product protected by the international copyright laws. © 2008 . All rights reserved.
The information contained within this document may be subject to change without prior notice
and non binding to the product makers. English edition – May 2009
For further information
please contract the Progea offices.
Our expert personnel are also available
for on site demonstrations and training.

Progea Srl Progea International Ltd

via S.Anna 88/E via Moncucco 7
I-41100 Modena Italy 6900 Lugano - Schweiz
tel +39 059 451060 tel +41 (91) 9676610
fax +39 059 451061 fax +41 (91) 9676611
info@progea.com international@progea.com
www.progea.com
Progea Deutschland GmbH
Italian Branch Marie-Curie-Str. 12
via XX Settembre 30 D-78048
Tecnocity Alto Milanese VS-Villingen - Deutschland
20025 Legnano (MI) Italy tel +49 (0) 7721 9925992
tel +39 0331 486653 fax +49 (0) 7721 9925993
fax +39 0331 455179 info@progea.de