TrakSYS™ Training

D ay 1
Training Overview
 3

Training Agenda

Day 1 Day 2 Day 3 Day 4 Day 5

TrakSYS Overview Content Pages Performance M anagement API Introduction Production Scheduling

Setup and Installation Values Dictionary Content Page Functionality Logic Service Alerts and Notifications

Configuration Basics Visual Pages Batching and Storage Data M anagement Service Inventory M anagement
Systems
Navigation Introduction Content Parts and Features TrakSYS Extensibility Statistical Process Control
Template Systems
Functionality and Data Users and Permissions Sites, Translations, and Audit Support and Resources
Task Configuration

Introduction Training

Advanced Training

Comprehensive Training
 4

Target Audience

Owners & Users Developers

Business Owner Light Logic
General Capabilities VB.NET and basic C#

Infrastructure Admin Complex Rules

IT / Automation C# and TrakSYS API

Configuration Admin Light User Interface

Business Rules Web Paradigm and Configurable Pages

Data Consumer UI Expert

Standard Reports and Pages HTML/ CSS/ JS/ ASP.NET C#

Business Developer BI Expert

Value Proposition and Features SQL and ASP.NET C#
 5

Training Format

Presentation and Discussion

Training topics focusing on concepts,
features and capabilities of TrakSYS™.
Questions ?
Ask them! We will…

1 Answer Now
Answer Later
Find the Answer
Arrange a Session

Lab Assignment Instructor Demonstration

Hands-on activity using training
PCs and TrakSYS™software.
3 2 Live demonstration of key concepts
from the presentation topic.
 6

Daily Schedule

75 Presentation and Discussion 75 Presentation and Discussion

08:30 – 09:45 13:00 – 14:15

30 Lab 30 Lab
09:45 – 10:15 14:15 – 14:45

15 Break 15 Break
10:15 – 10:30 14:45 – 15:00

60 Presentation and Discussion 60 Presentation and Discussion

10:30 – 11:30 15:00 – 16:00

30 Lab 30 Lab
11:30 – 12:00 16:00 – 16:30

60 Lunch
• Labs may crossover into Breaks
12:00 – 13:00
• Feel free to Come and Go
• Strive to stick to Schedule
 7

Orange County Companies

Demonstration and Training Environment

Throughout the training course, a fictitious plants called Orange County
Vitamin and Orange County Foods will be used for demonstration and as a
target for hands-on lab exercises.

Plant Operations
The Orange County Vitamin plant includes vitamin raw material processing
(Batch), Warehousing (Storage), and Packaging/ Finishing (Discrete).

The Orange County Foods plant includes similar capabilities, but has been
designed to display additional features that are new to TrakSYS 11.
TrakSYS Overview
 9

Training Objectives

Provide a general introduction to the TrakSYS concept, business

goals and technical overview.

Describe the high level component architecture and introduce

some of the key services, applications and user interfaces that
make up the TrakSYS platform.
 10

Business Overview

The Business Overview video provides a high level

review of TrakSYS™from a functional and goal
perspective.
 11

Technical Overview

The Technical Overview video provides a high level

review of TrakSYS™from an component and
application perspective.
 12

Component Overview

Web Browser Standard APIs

Business and Operations Users Business
Line Managers, Quality, CI, Lean, Plant Applications
Managers, Corporate, etc. ERP, Quality, Maintenance, Batch,
Planning & Scheduling, etc.

TrakSYS™ Platform
Real-Time Data Collection,
Execution, Alerts, Reports, Analytics

IIoT • PLC • OPC • API • CSV • Structured Data Files

Receiving • Testing • Preparation • Production • Packaging • Warehouse • Shipping

 13

Component Overview

Installation TrakSYS™
Client
Manager Web

Application Data
Logic Historian Maintenance
Services Management

Data SQL Server 2012+

 14

Logic Service

• Real-time Data Collection Engine

• Receives inputs from OPC Sources
• Executes Business Rules to calculate Events, Tasks,
Steps, Transfers and Sample Processing
• Calculates KPIs
• Broadcasts Notifications
• Collects data from I/ O, LIMS, PLCs, Historians,
SCADA, ERP, and other Business Applications

Supports Multiple and/ or Distributed Instances

 15

Historian Service

• Monitors and records changing TrakSYS™Tag values

for historical Trending and Analysis
• Supports Store and Forward when the TrakSYS™
Database is Unavailable
• Supports algorithmic Data Compression (SLIM 3)
• Licensable TrakSYS™component Tag History
Definitions Required

Supports Multiple and/ or Distributed Instances

 16

Data Management Service

• Independent multi-threaded service used for

executing Non-Real Time Operations
• Facilitates processing large Data Aggregation
• Connects to external Business Systems for Import
and Export of Configuration and Data
• Schedules periodic execution of scripted Modules

Supports Multiple and/ or Distributed Instances

 17

Maintenance Service

• Continually executing in the Background of every

TrakSYS™Installation
• Executes core built-in TrakSYS™application
Functions
• Monitors and Trims Database Log Tables
• Distributes programmatic Notifications
• Executes built-in KPI and Event data modifications
after Updates and Edits
Setup and Installation
 19

Training Objectives

Provide an overview of the setup and installation process for the

TrakSYS software and its components.

Demonstrate some of the typical setup and installation activities

involved in deploying the software to a new server/ environment.
 20

Installation Overview

1
Platform Pre-Requisites
Windows Server 2012 R2/ 2014/ 2016/ 2019, .NET Framework and Internet Information
Services. Installation guides available on the TrakSYS™Support Site.

2
SQL Server
Version 2012 / 2014 / 2016. Standard or Enterprise. Scripted install from the TrakSYS™
setup DVD/ ISO or manual installation instructions available on the Support Site.

3
TrakSYS Setup
The TrakSYS™setup executable deploys all of the executable files to the target machine.
Additional setup options and configuration is continued from the Installation Manager.

4 TrakSYS Installation Manager

After the TrakSYS™files are deployed, the Installation Manager is used to configure the
database, connection, services, web and other platform settings.
 21

Installation Manager

• Primary tool used to manage the installation of

TrakSYS™services and components.
• Manage, troubleshoot and maintain an
implementation after the initial deployment.
• Replaces and consolidates several components from
previous TrakSYS™versions.
• Main screen acts as a status overview of the various
elements of the installation, as well as a menu to
interact with details and options in each section.
 22

Database Management

Database Connection Overview

Displays the current status of the application connection to the
TrakSYS™database. Including login information, SQL version, and
TrakSYS™version.

Database Operations
• Edit Connection
• Repair Logins
• Create / Upgrade Database
• Backup / Restore Database
• Transfer Export/ Import

Audit Trigger Operations

(available when TrakSYS Audit features are licensed)

• Create Audit Triggers

• Delete Audit Triggers
 23

License Management

License Overview
Displays the current TrakSYS™license and status. The TrakSYS™
license file must be imported into the database and activated in order
for the software and components to be utilized.

License Operations
• Import License
• Delete License
• Activate License Online
• Activate License M anually

License Features
Lists the TrakSYS™features from the current license. Allows the
assignment of server name (Host) to license features which are
required to be locked to a specific host machine.
 24

Service Management

Services Overview
Lists the TrakSYS™services that are currently installed on the local
server. Includes the current server running status.

Service Operations
• Install Logic
• Install Historian
• Install Data M anagement
• Install M aintenance

Service Control
TrakSYS™services can be started, stopped and restarted from the user
interface. They can also be controlled from the standard Windows
Services management interface.
 25

Web Application Management

Web Application Overview

Displays the status of the TrakSYS™web user interface application
that is installed on Windows Internet Information Services (IIS).
TrakSYS™requires specific IIS features to be installed on the server in
order to support its deployment and use.

Web Operations
• Setup TS Web
• Remove TS Web
• Setup / Remove WEBTrak (legacy)
 26

Other Features

Reporting Services
Allows management of TrakSYS™reports hosted in SQL Reporting
Services. Includes Reporting Services status and operations for
installing and removing standard reports to/ from the Reporting
Services platform.

Sites
Allows for the creation and management of TrakSYS™Sites. This
feature is only available when the appropriate multi-site license is
present.

Diagnostics and Troubleshooting

Access to OPC and M ail connection statuses, and TrakSYS™log/ trace
entries. Includes operations to export application messages for
convenient transport to support staff.
 27

Installation Success

Upon successful setup and installation configuration,

the TrakSYS™application user interface should be
accessible by navigating a browser to…

http: // servername / ts
Navigation Basics
 29

Training Objectives

Introduce the fundamentals of the TrakSYS web user interface.

Become familiar with the types of Pages, user interface patterns

and navigational elements.
 30

Page Hierarchy

Site Sections Hub 1s Hub 2s Hub 3s

OCV
Batching
Tableting
Packaging
Overview
Reports
Events
MTBF
OEE
Avail
Perf
Qual
 31

Page Hierarchy
Site Section

Hub 1
Hub 2
 32

Slices

Slice 1 Slice 2 Slice 3

 33

Item Slice

• Entity Name
• Common Actions
• Key Properties
• Related (typically Child) Entities
• Actions
 34

Breadcrumbs
Modeling and Configuration
Areas and Systems
 36

Training Objectives

Discover how TrakSYS can be used to model a physical production

environment and equipment using Areas and Systems.

Define and explain the types of Systems that can be modeled in

TrakSYS to handle different types of production processes.
 37

Asset Hierarchy

• Name in configuration: Sites, Areas,

Enterprise
and Systems
• Represent / Model the physical
Production Environment
Site
• Specific equipment modeled by
TrakSYS™Systems and Sub-Systems
• Discrete Batching Tableting Packaging Storage
Area Area Area Area
• Batch
• Storage
Line 1 Line 2

Filler Labeler Caser Filler Labeler Caser

 38

Areas

• An Area represents a subset of the

production environment or logical
grouping of plant assets.
• Areas exist to Group and Organize
manufacturing Systems
• Hierarchal structure supported:
Areas may contain other Areas
• Can be modeled using the ISA S95
Naming Conventions (Enterprise,
Site, Area)
 39

Discrete Systems

• Used to model Manufacturing

Equipment which produce / process
Discrete Items (Cans, Cases,
Widgets, etc…)
• May represent a Production Line
(S95), or Work Cell (S95) / Individual
Equipment (e.g. Packaging Line,
Labeler, Caser, Sealer, etc…)
• May include Sub-Systems (Work
Cells) to represent smaller
components within the main System
• Contain child configuration elements
to model Stoppages, Tasks, SPC
Sampling and KPI Calculations
 40

Batch Systems

• Used to model Manufacturing

Equipment which produce / process
Batch or Volumes of Material
(Process Cells (S95) / Batching Lines)
• Contain one or more Sub-Systems or
Units (e.g. Blender, Mixer, Granulator,
and Dryer)
• Contain child configuration elements
to model Batch Steps, Events, Tasks,
and SPC Sampling
 41

Storage Systems

• Used to model Manufacturing

Equipment which store a Quantity of
Material (Storage Zones (S95))
• Facilitate Inventory and Material
Management Solutions
• Contain child configuration elements
to model Material Transfers , Events,
Tasks, and SPC Sampling
 42

Template Systems

• Used to configure and maintain Packaging

multiple Systems with Identical Template
Structure and Behavior
• Child Systems inherit Shared
Filler Labeler Caser
Properties and Settings from the
parent Template
• Some Properties and Settings are
equipment specific and configured at
the Child Level

Packaging Packaging Packaging

Line 1 Line 2 Line 3

Filler Labeler Caser Filler Labeler Caser Filler Labeler Caser

 43

Demonstration

• Install TrakSYS™from Setup • Configure

• Installation Manager • Area
• Create Database • Discrete System
• Import / Activate License • Sub-System
• Install Services • Show Options
• Setup TS Web • Batch Systems
• TS Web Navigation • Storage Systems
• Sections • Template Systems
• Hubs
• Slices (Configuration)
Lab 1
Modeling and Configuration
Tags
 46

Training Objectives

Learn how TrakSYS monitors Tags from external sources such as

plant equipment, PLCs, and other production systems.

Understand how business rules and conditions can be created

using different TrakSYS Tag types to combine and calculate new
Tag values.
 47

What is a Tag?

• Represents a single, real-time Value from the

Manufacturing Process
• A Tag Value is defined / typed as …
• Discrete (0 or 1)
• Integer
• Float
• String
• Tag Sources include…
• Inputs from the Physical Process (PLCs)
• Logical Expressions and Scripts
• Internal TrakSYS™Statuses
• Solution Manipulated Virtual Addresses
 48

Tag Examples

LINE_1_FILLER_JAM LINE_5_PRODUCT_SKU
A Discrete value monitored from the Filler PLC indicating if A String value stored in the TrakSYS™database, populated via
the machine is stopped due to a Jammed condition. user interface by users when a new Production Run is started.

LINE_3_GOOD_CASES LINE_4_CURRENT_EVENT
A Float counter value monitored from the end of the Line A String value calculated and exposed from TrakSYS™
indicating the number of good cases packaged. indicating the name of the currently active System Event.

LINE_2_RUNNING
A Discrete value calculated in expression / script which is true
(1) when the Total Counter is incrementing.
 49

Tag Groups

• Used to organize Tags for Human Convenience

• Open / Hierarchical Structure [ Product ]
P1.PRODUCT.BOTTLE_SIZE
P1.PRODUCT.BOTTLES_PER_CASE
• Suggested Tag Group Naming Convention…
• Spaces
Filler
• Normal Case P1.FILLER.MOTOR_RUNNING
P1.FILLER.TIPPED_BOTTLE

• Suggested Tag Naming Convention… Line 1

• No Spaces, Underscore for Spaces

Packaging Labeler
• ALL CAPS
Line 2
• Mimic Tag Group Hierarchy
• Dots Separate Tag Groups Caser
 50

OPC Tags

• Represent real-time data points from

OPC Compliant Servers
• The Item Name Property specifies a
unique, fully qualified Tag address from
the target OPC Server
• Each Tag is related to an OPC Access
Name which defines the connection to
the OPC Server
 51

OPC Access Names

• Defines an OPC data source and how TrakSYS™

connects to OPC Servers
• Key Properties
• Node
IP Address or PC Name

• OPC Server Name

Programmatic Name of OPC Server

• Access Path
Optional Item Name Prefix

• Parent entity referenced by each OPC Tag

 52

Logic Tags

• Logic Tags allow the combination and

operation on existing Tags within TrakSYS
• Create Business Rules and Logic without:
• Reprogramming PLCs
• Updating / Changing existing
AND
Automation
• Customization using Scripting
• Expose the result of the Logic Tag operation
as a new Tag Value
 53

Logic Tags

Compare Latch
Takes 2 input values (Tags or Constants) and compares them Takes 2 Discrete Tag inputs, the first latches the result value,
producing a Discrete result value. the second clears it. Produces a Discrete result value.

Boolean Switch
Takes N input Tags and applies a Boolean condition (AND, Takes in a single Tag value and returns a result based on a
OR, NAND, etc..) producing a Discrete result value. comparison table of input -> output values.

Calculation Aggregate
Takes 2 input Tags and applies an arithmetic operation (+, -, *, Takes N input Tags and applies an aggregate operation (SUM,
/ , %, etc…) producing a new result value. AVG, etc…) producing a new result value.
 54

Script Tags

• Define a complex logical Expression or

Calculation within a single Tag
• Simplify the implementation of complex
Business Rules
• After executing, returns a single result Value
• Script Types
• Simple (VB.NET)
• Advanced (C#.NET)
• Executed synchronously within the Logic
Service memory and Scans
• Recommended to Avoid heavy Data
Aggregation and communication with External
Systems
 55

Counter Tags

• Used to monitor and accumulate an incrementing

Automation Input (Tag)
• Accumulates input Tag changes since the
previous Logic Service Scan
• Produces the aggregated input increase as the
resulting Tag Value
• Contains settings for Max Increment per Scan
and Input Multiplier
 56

State Tags

• Returns internal Logic Service state Values

• Data Type chosen based on the State Tag Attribute
• Entity Types
• Access Name
• Event Definition
• Function Definition
Active
• Logic Service
• KPI Calculation
Scheduled

• KPI Counter Running Seconds

• Sample Definition
• Schedule
• System
• Tag
 57

Virtual Tags

• Used to store real-time data Values that are not

available from External Sources
• Values are maintained in the TrakSYS Database
• Values are modified using TrakSYS User
Interfaces Functions, APIs or directly in the
Database
• Examples include…
• Current Job Name
• Current Product
• Production Theoretical Rate
• Counter Multipliers
 58

Template Tags

• Placeholder Tags assigned to properties in and

beneath a Template System
• Aid in Tag Duplication when a new Template
System is Created
• When Template Tag Duplication occurs, all
Template Tags from the Template Systems are
copied to the target Child System Structure
 59

Additional Tag Settings

• Persist Value Changes to Database

When checked, the Logic Service will update
the value of this Tag in the database whenever
it changes (default True).
• Force Evaluation
When checked, the Logic Service will evaluate
this Tag every scan, regardless of change
(default False).
• Prerequisite Tags
When specified, the Logic Service will ensure
the referenced Tags are evaluated before the
parent Tag. These are generated
automatically by default or a manual list of Tag evaluation occurs intelligently from the bottom up,
Prerequisite Tags can be specified. based on when referenced Prerequisite Tags change value.
Smart Tags and
Smart Devices
 61

Training Objectives

Become familiar with the Smart Device hardware available for use
with the TrakSYS software.

Understand how to configure Smart Tags to communicate with

Smart Devices.
 62

Smart Devices
TrakSYS Smart TrakSYS Smart
Data Collector Coordinator

Communication Module Sensor Connection Web Interface Wireless Hotspot

Lightweight RF M12 5-Pin Connector Simple Configuration Local wireless hotspot for easy,
Wireless Mesh Network Nearly any 3rd Party Sensor Settings and Diagnostics standalone configuration

Power Logic Module Processing Module Ethernet

Quick Disconnect Local Logic Processing Data Push Wired connection to TrakSYS™
12-30VDC (3W) Data Push and Heartbeat Collector Heartbeat Network

Sealed Mounting Power Antenna

IP65 Rated Enclosure Flexible Attachment and Standard AC Adapter Lightweight RF Wireless with
Mounting Options Smart Data Collectors

CE/ FCC Certified

 63

Smart Architecture

Add and Expand

Add new Data Collectors to
the Edge of the Network as
Needed

Data Relay
Data is relayed to the
Coordinator through the
closest Device

Zero Configuration
New Data Collectors connect
and begin Communicating
Automatically
 64

TrakSYS Connectivity

Network
Boundary / Firewall
TrakSYS™ Smart
Server Coordinator

Integrated Firewall Friendly One-Way Compact

Web Service endpoints are Port 80 is the only required Communication flows only Lightweight messages are
included with TrakSYS™. No firewall configuration. This from the Coordinator to the sent to the TrakSYS™server
need for additional is typically already allowed. TrakSYS™server, making on data change and
communication drivers. internetwork configuration heartbeat.
requirements more secure.
 65

Smart Device Web Service

• Data Collectors
Identifies the Smart Collectors that are
connected to the Coordinator, including
their unique address and current value.

• Network Information
Shows the information related to
connecting the Smart Devices together,
as well as pointing the coordinator to the
appropriate TrakSYS installation.

• System Status
Displays key indicators of the
Coordinator’s current state for
troubleshooting purposes.
 66

Smart Tags

• Address
Provide the matching Address from the
Smart Coordinator screen. If configured
correctly, the Coordinator will
automatically connect the two and will
show the connection in the Coordinator
interface.

• Standard Properties
All other properties match those of a
Virtual Tag.
Modeling and Configuration
Tag Historian
 68

Training Objectives

Become familiar with the Historian Service and related

configuration entities.

View the related Content Pages for Historian Solutions.

Additional information about Content Pages will be covered
in later sections.)
 69

Historian Service Review

• Monitors and records changing TrakSYS™Tag values

for historical Trending and Analysis
• Supports Store and Forward when the TrakSYS™
Database is Unavailable
• Supports algorithmic Data Compression (SLIM 3)
• Licensable TrakSYS™component Tag History
Definitions Required

Supports Multiple and/ or Distributed Instances

 70

Historian Service Configuration

• Name
Display name for the service
• Computer Name
Name of the service instance for this entity
• Store and Forward Path
Server location for where to store records
locally if connection is lost
 71

Tag History Definition

• Name
The field that is used for display in reports
• Mode
The method for determining when a value will
be recorded
• M aximum Interval
The maximum time that can pass before
automatically recording a value automatically.
• M aximum Deviation
The maximum (flat value or percentage)
change that can occur before recording a
value automatically.
• Expiration
How many hours before the Historian Data is
automatically deleted. Set to 0 to disable.
 72

Historian Database

Database can be created One table will be created for All Historian data will
through the TrakSYS each Tag Historian Definition be stored in the
Installation Manager that is configured Historian Database
 73

Historian Service

Once configured, the Historian Additional information for The Historian Service will automatically
Service can be tracked through managing the service can be stop running if no Tag Historian
the Administration Section found here, including Logs Definitions are assigned to it
 74

Historian Content Page

Easy picker system to display Specialized charting for Additional parts available for
desired Historian information historical trending capabilities customization needs
 75

Demonstration

• Configure a Tag Group • Configure the Historian Service

• Configure a Virtual Tag • Create the Historian Database
• Configure an OPC Access Name • Create a Tag History Definition
• Configure an OPC Tag
• Configure a Compare Tag
• Highlight Tag Picker
• Configure a Script Tag
Lab 2
 Logic Service
and Tag Interaction
 78

Training Objectives

Understand the TrakSYS administrative user interface for

monitoring the status of the Logic Service (and other TrakSYS
services).

Learn how to monitor Tag value changes in real-time, as well as

modify Tag values for simulation and testing.
 79

Logic Service Hub

• Located in the Administration

Section under the Services Hub
• Hub is automatically created for
each Service Instance
• Service specific Status, Related
Items and Actions
• Service Control is handled from
outside the Web Application

The Service Pages can be popped-out to a more compact

form factor for constant display while working.
 80

Logic Service Tags

• Monitor real-time Tag Values being

managed by the Logic Service
• Only functional when the Logic Service
is Running
• Filter Mode
Set up to 8 Tag Name Filters
• Updating Mode
Live Tag Values are Displayed
• Red = Bad Quality
The Tags page can be opened in more than one
• Green = Recently Changed
Tab or Window simultaneously. Common Tag
filter arrangements can be saved using the • Values may be edited for Simulation and
browser Favorites. Testing (Virtual and OPC only)
 81

Service Control

• TrakSYS
Services can be started, stopped, and
re-started using the Services page in
the TrakSYS Installation Manager
application.
• W indows
Services can be started, stopped, and
re-started using the Windows
Services applet.
• PowerShell
Services can be started, stopped, and
re-started using a PowerShell
command with the appropriate
credentials
Modeling and Configuration
System Functionality
 83

Training Objectives

Become familiarized with the various System Definitions, their

basic structures and intended uses.

Later sections of the training course will cover each of these

functions in more detail.
 84

System Functionality

Batch Systems Storage Systems

• Function Definitions (Steps) • Transfer Definitions (Material)
• Task Definitions (Quality) • Event Definitions (Downtime)
• Event Definitions (Downtime) • Task Definitions (Quality)
Discrete Systems
• Sample Definitions (SPC) • Sample Definitions (SPC)
• Event Definitions (Downtime)
• KPI Calculations (OEE)
• Sample Definitions (SPC)
• Task Definitions (Quality)
 85

Event Definitions
Discrete, Batch or Storage Systems

Packaging Line 1 Configuration

• Represent configurable data entry fields to be collected during
Changeover execution of a specific Event
• An Event represents a span of time (typically downtime)
Filler Event Definition associated with a specific asset (System)

Jam • Configurable at the System OR Sub-System Level

• A Discrete Trigger Tag property indicates when an Event Starts
Tipped Bottle and Ends

Labeler
Execution
Jam
Event Records • Loaded and executed by the Logic Service
No Labels • Events contain reference to related information such as Job,
Batch, Product, Shift, OEE Type, Category, etc…
• Only one Event at a time can be active for a given System *
 86

Event Definitions: Examples

Discrete, Batch or Storage Systems

General Fault Maintenance Lunch

• Trigger Source: • Trigger Source: • Trigger Source:

Automation Manual Logic Tag (Daily at Noon)
• OEE Type: • OEE Type: • OEE Type:
Availability Loss Availability Loss Not Scheduled
• MTBF Type: • MTBF Type: • MTBF Type:
Failure Non-Failure Excluded
• Requires User Input: • Requires User Input: • Requires User Input:
Yes No No
 87

Function Definitions
Batch Systems Only

Batch Line 2 Configuration

• Allows the real-time examination of an input condition to
Scale record instances of Batch Step records in the TrakSYS Database
• A Batch Step represents a span of time that a Batch System is
Load engaged in a specific activity (Step)
Function Definition
Measure • Configurable at the Sub-System Level Only
• A Discrete Trigger Tag property indicates when a Batch Step
Clean Starts and Ends

Mixer
Execution
Load • Loaded and executed by the Logic Service
Batch Step Records
• Batch Steps contain reference to related information such as
Mix Job, Batch, Product, Shift, etc…
• It is possible for multiple Batch Steps in a single Sub-System to
Clean
be simultaneously active, with each Batch Step having a
corresponding Batch Step Record
 88

Function Definitions: Examples

Batch Systems Only

[ Scale ] [ Dryer ] [ Granulator ]

Measure/ Weigh Heat Up Unload

• Trigger Source: • Trigger Source: • Trigger Source:

Manual Automatic Manual
• Parameters: • Parameter: • Parameters:
None Temperature RPM
• Used in Recipes: • Used in Recipes: • Used in Recipes:
ADRA (Step 2) ADRA (Step 6/ 10) DRIS (Step 16)
DRIS (Step 3) DRIS (Step 8) SAFS (Step 17)
SAFS (Step 3) SAFS (Step 9)
 89

Sample Definitions
Discrete, Batch or Storage Systems

Packaging Line 1 Configuration

• Defines the parameters for taking quality SPC samples of a
Bottle Inspection specific type to record instances of Sample Sub-Group records
in the TrakSYS Database
Fill Weight • An Sample Sub-Group represents a set of 1-N samples
Sample Definition measured together and associated with a specific asset (System)
• Configurable at the System Level Only
• Constants or Tags can be defined to specify SPC Limits

Sample Sub-Group Records Execution

• SPC data typically logged against a Sample Definition via user
interface data entry Forms
• Sample Sub-Groups contain reference to related information
such as Job, Batch, Product, Shift, etc…
• Automated SPC sampling can be achieved using the API and
Scripting to capture values and create Sample Sub-Groups
 90

Sample Definitions: Examples

Discrete, Batch or Storage Systems

Fill Weight Temperature Bottle Inspection

• Type: • Type: • Type:

Variable Variable Attribute
• Control Limits: • Control Limits: • Control Limits:
61-63g Auto-Calculate Auto-Calculate
• Specification Limits: • Specification Limits: • Specification Limits:
>60g 68-72 ûF None
• Rules: • Rules: • Rules:
Western Electric 6 Trending Western Electric
Above/ Below CLs
 91

Task Definitions
Discrete, Batch or Storage Systems

Packaging Line 1 Configuration

• Allows the real-time examination of an input condition to
Hourly Log Entry record instances of Task records in the TrakSYS Database
• A Task represents a request with pre-defined user inputs
Filler Task Definition required (a form) associated with a specific asset (System)

Safety Check • Task Definitions are configured to require 1 or more user input
fields (Task Form Items)
• Configurable at the System OR Sub-System Level
• A Discrete Trigger Tag property indicates when a Task is
Generated

Task Records Execution

• Loaded and executed by the Logic Service
• Tasks contain reference to related information such as Job,
Batch, Product, Shift, etc…
• Task Forms are implemented and completed in the TS Web
User Interface
 92

Task Definitions: Examples

Discrete, Batch or Storage Systems

Prepare Forms Maintenance Request Filler PM

• Trigger: • Trigger: • Trigger:

Job Start Manual Machine Bottle Count
• Time to Complete: • Time to Complete: • Time to Complete:
15 Minutes 60 Minutes 30 Minutes
• Evaluation Logic: • Evaluation Logic: • Evaluation Logic:
None can Fail Always Pass Manual Pass/ Fail
• Inputs: • Inputs: • Inputs:
BOM Verified Affected Machine Inspect Fill Heads
Safety Sign-off Cause of Issue Inspect Valve
Quality Standards Resolution Clean Machine
Reference
 93

Transfer Definitions
Storage Systems Only

Storage Silo 3 Configuration

• Allows the real-time examination of an input condition to
In from WH record instances of Transfer records in the TrakSYS Database
Transfer Definition
• A Transfer represents a movement of a specific Material to or
Out to Mixer from a Storage System
• Configurable at the System Level Only
Clear
• A Discrete Trigger Tag property indicates when a Transfer
Starts and Ends

Transfer Records Execution

• Loaded and executed by the Logic Service
• Transfers contain reference to related information such as Job,
Batch, Product, Shift, etc…
• Data records include captured information such as the Material
Code and Quantity that is Transferred
 94

Transfer Definitions: Examples

Storage Systems Only

Transfer In Transfer Out Set/ Adjust

• Trigger: • Trigger: • Trigger:

Manual Automatic Manual
• Context Input: • Context Input: • Context Input:
Manual Form Input Barcode Scan Machine Reading
• Target System: • Target System: • Target System:
Loading Bay A Shipping Bay B (Self)
 95

Demonstration

• Configure an Event Definition • Show the Logic Service Hub

• Configure a Function Definition • Filter Tag List
• Configure a Sample Definition • Change a Tag Value
• Configure a Transfer Definition
• Configure a Task Definition
• Assign Task Form Items
Lab 3
Entity Introduction
 98

Training Objectives

Understand the basic pattern of structures in the TrakSYS

Database and their matching TrakSYS Models.

Later sections will cover Entity Relationship Diagrams (ERDs) of

entities in more details.
 99

Entity Example

Entity: Event
• Entity
Everything that is stored in TrakSYS database DbEvent tEvent
is linked to a specific entity, whether it is data
or configuration or something else.
• DbEntity Model
In script, every entity has a matching DbEntity
model that can be used to interact with that
type of information.
• tEntity Table
In the database, every entity has a matching
tEntity table that will contain all the data for
that type of information.
 100

Event Data
Linking to Sites

Each Entity can be linked to a specific Site through foreign Keys.

This allows data to be reported on by a number of specific, asset-based groupings.

tSite tArea tSystem tEventDefinition tEvent

PK ID PK ID PK ID PK ID PK ID

SiteID AreaID SystemID EventDefinitionID

SplitEventID

LinkedEventID
 101

Event Data
Linking to Context

Data records also have contextual identifiers, both standard and implementation specific ones.
This allows data to be reported on by a number of specific, contextual and implementation-specific groupings.

tProduct

PK ID tEvent

PK ID tShiftHistory
tJob tShift
ShiftHistoryID PK ID
PK ID PK ID
ProductID ShiftID

tBatch JobID TeamID tTeam

PK ID BatchID
PK ID
 102

Event Data
Example Use

• The DbEvent object can be used in page

development to display information to users.
Modifications can then be made to the object.
• Using the API, the DbEvent object can also be
used to update their matching tEvent table
record.
• The tEvent table can be reported against
using standard web parts and pages.
• This pattern allows for manual editing and
interactions with the TrakSYS data. This will
be covered in more detail in later sections.
 Modeling and Configuration
Schedules, Products, Jobs and Capture
 104

Training Objectives

Introduce additional configuration entities and functionality

designed to monitor and store information related to the
manufacturing process.

Entities such as Schedules, Product Information, Job and Batch as

well as extensible data Capture scheme allow for additional
context to be added to the core System data captured by TrakSYS.
 105

Scheduling

• Schedules Shift
An arrangement of Shift and Team Schedule

assignments over a repeating calendar

pattern. Used by the Logic Service to references

associate personnel to collected data such as

Events and Tasks.
• Shifts Logic
Represent named time periods for operators Service
records
or Teams (Day Shift, Night Shift, etc…)
• Teams
Represent a specific group of operators that Event Data
may be assigned to work during a particular Jam on Filler @ 2:54 PM during Day Shift, Team B
Shift (Team A, Team B) Changeover on Line 1 @ 3:02 PM during Night Shift, Team C
…
 106

Schedule Pattern

• Schedules may include one or more Schedule

Patterns
• Logic Service uses the Schedule Pattern
with the most recent Effective Date/ Time
• Represents a repeating arrangement of Shifts and
Teams (Schedule Pattern Items)
• Start Date/ Time and Duration
• Shift and Team
• Gaps are Allowed (no Shift/ Team is
associated)
 107

Products

• Products represent the finished good that are

produced from a manufacturing process (System)
Adravil Prospirim Safsprin
• A unique Product Code (SKU, Item Number,
etc…) identifies each Product
• May contain user defined attributes such as
Theoretical Rate or Multipliers.
• May contain a list of Materials and quantities that
are required to produce the Product (BOM) Packaging Line 1

• When assigned to a Batch System, Recipes may

be defined to represent the formula or set of
production steps for creating the Product
 108

Product Configuration

Adravil

• Product Scheme (Packaging Lines)

A set of user defined Product Attributes for
which values can be provided for each
Product.
• Product Set (Packaging Line 1)
A list of Products that can be produced from a
System or group of Systems. Bottles per Minute

• Product M ap Bottles per Case

A mapping that defines specific Tags to be
populated with Product Attributes from a
designated Product Set. P1.PRODUCT.BOTTLES_PER_MINUTE

P1.PRODUCT.BOTTLES_PER_CASE
 109

Product Scheme Example

Product Scheme
Attribute names and data type can be changed.
Disabled attributes will be hidden.
 110

Product Map Example

System : Packaging Line 1

An external process The Logic Service
Tags detects the Tag
changes the
• P1.PRODUCT.CODE (current product running) change and
P1.PRODUCT.CODE
• P1.PRODUCT.BOTTLES_PER_MINUTE Tag value to ADRA determines that the
Product Set for Line
• P1.PRODUCT.BOTTLES_PER_CASE
1 is Packaging Line 1
Product Scheme : Packaging Attributes Products
• Bottles per Minute (BPM) 1 2
• Bottles per Case (BPC)
Product Set : Packaging Line 1 Products
• Adravil | ADRA | 200 BPM | 24 BPC
• Prospirim | PROS | 150 BPM | 36 BPC Logic Service copies Logic Service locates
BPM and BPC the Product
Product Map : Packaging Line 1 Map
attributes from the matching the Code
• Monitors Tag P1.PRODUCT.CODE for changing Value ADRA Product to ADRA within the
• Maps attributes from Product Set Packaging Line 1 to specific Tags for the the Line 1 Tags Product Set
Packaging Line 1 System based on the
• Bottles per Minute (BPM) -> P1.PRODUCT.BOTTLES_PER_MINUTE Product M ap

• Bottles per Case (BPC) -> P1.PRODUCT.BOTTLES_PER_CASE 4 3

 111

Product Map Example

Product Configuration Product Mapping Logic Evaluation

Product is part of a Product Set and has Attributes Attributes are mapped When the Product Map Tag changes, Logic Service finds
exposed based upon the Product Scheme to specific Tags. the matching product and updates the other tags
 112

Jobs

• Jobs represent a production run of a specific

Product on a specific System or Systems Events

• Other common terms for Jobs are Process Order,

Order, (Production) Run, etc… Steps KPIs

• All production data collected by TrakSYS (Events,

KPIs, Steps, Tasks, Samples, Transfers, etc..) can
Job
be related to a Job

Transfers Tasks

Samples
 113

Job Configuration

• The Job Tag should contain a unique identifier for

the current Job running on the System
• The Job Planned Size Tag should contain the
target size (units to be produced) for the current
Job
• TrakSYS creates a new Job record for a System
when the Job Tag changes Value
 114

Batches

• Batches are smaller sub-sets of production within Scale

Job : ADRA-7655
a Job
Batch : 3
• Batches apply only to Batch type Systems

System : Batch Line 2

• A single Batch Job may contain one or more
Batches M ixer
Job : ADRA-7655
• A single Batch System (containing many Batch
Batch : 2
Sub-Systems) may be processing more than one
Batch Simultaneously
• Each Batch Sub-System may only be operating on
Dryer
one Batch Simultaneously Job : ADRA-7655
Batch : 1
 115

Batch Configuration

• Job and Batch Tags are configured at the Sub-

System level in Batch Systems
• A Batch System must have at least one Sub-
System
• The Job Tag should contain a unique identifier for
the current Job running on the Sub-System
• The Batch Tag should contain a unique identifier
for the current Batch running on the Sub-System
• TrakSYS creates new Job and Batch records for a
System when the Job and Batch Tags change
Values
 116

Capture Schemes

• A Capture Scheme is a set of user-defined data

points to be recorded and related to Production
Data
• Job Capture Schemes
Up to 20 additional values can be recorded with
Job Records
• System Capture Schemes
Up to 10 additional values can be recorded with
Event Records
• KPI Capture Schemes
Up to 10 additional columns can be recorded
with KPI Interval Records
 117

Capture Tags

• Capture Tag associations map a specific Tag value

to a Capture Column for a given System or KPI
Calculation
• The Logic Service automatically populates the
Capture Column with the Tag value as Events,
Intervals and Jobs are Created
 118

Capture Scheme Example

Configured Capture Scheme with tags. External Source sets these tag values.

Job Data Record created contains

Job with scheme is processed by logic service.
capture information from tags.

Name: P.5825
Product: Adravil200
Capture01: 80
Capture02: 30
Capture03: XYZ Corp
 119

Demonstration

• Configure Shifts and Teams • Configure a Job Tag Assignment

• Configure a Schedule • Configure Batch Tag Assignment
• 14 Day Pattern • Configure a Job Capture Scheme
• Configure Products • Job Capture Tag Assignment
• Scheme
• Set
• Products
Lab 4