Line, Equipment, & Machine Monitoring for Efficiency, Capacity Utilization, Defects, Yield, Down-Time, Rejects, Metrics, Key Performance Indicators (KPI) Management Software

Monitor Master software is a collection of expert technologies developed over many years that improves operations in both local and remote operations.  Integration of control, monitoring, and management information systems allows different users to see different aspects of the same system.  For example, operators see things they can touch: lines, machines, equipment.  Maintenance personnel see alarms, diagnostics, and historical detailed traces.  Managers and Process Engineers see production and quality reports, inventories, databases of metrics and key performance indicators.  You need a system that handles all of these requirements. 

Use Line Equipment Machine Monitoring for Efficiency Capacity Utilization Defects Yield Down-Time Metrics Key Performance Indicators KPI Management Software to Improve Operations

• Lower operating costs.  Saves thousands of dollars per computer per year over traditional SCADA systems. 
• Have more predictable operations, less variance, more consistency, higher quality, fewer mistakes
• Automate and optimize operations to reduce loss
• Real-time information sent to users around the world
• Regulatory data is monitored, warned about, alarmed
• Quality data is monitored, analyzed, recorded and reported.  Or can interface with existing quality software. 
• Speed up operations by discovering bottlenecks and limiting processes
• More and better information about operations allows you to continuously improve your operations and keep making them faster, better, and cheaper. 
• Integration both horizontally and vertically.  From raw material unloading to finished goods loading and from low level sensors up to information systems and mainframe / ERP integration. 
• Create custom recipes for each customer so that each customer can get exactly what they want
• Reduce the number of operators required to run facilities
• Automatic reordering option watches usage and level to report when tanks are projected to run out.  Gives management a forward looking view of when they will run out of critical supplies
• "What If" analysis.  For example, how many gallons of product E can I make with existing raw materials?  How many gallons of product F can I make with all the raw materials in the southeast?  What is my limiting raw material? 
• Can be implemented in phases to reduce risk, downtime, or replace legacy systems. 
• Can provide optimal planning and scheduling systems
• Uses Microsoft software to lower up-front costs, allows you to do more for less
• Scalable from a single tank with a small PDA interface to global operations
• Power monitoring helps reduce peak power usage.  Can schedule processes that use a lot of power for non peak times. 
• Discover your biggest problems, bottlenecks, and limiting factors
• Instead of having the same IT infrastructure as everyone else -- now you have a competitive edge with a customized solution that optimizes your processes. 

Line Equipment Machine Monitoring for Efficiency Capacity Utilization Defects Yield Down-Time Metrics Key Performance Indicators KPI Monitoring System

• There is no software limit to the number of tanks you can put on one computer.  The number of tanks is limited by the memory and speed of the computer, and functionality that you require.  However, for redundancy purposes we recommend that you use more computers.  There is no additional charge to copy our software to more than one computer at the same plant, company and site.  If one Monitor server goes down, only those tanks disappear from the rest of the system.  By using proper procedures it only takes minutes to insert a new computer, copy the backup files from the server, and restart the Monitor server. 
• Uses product and interface levels
• Uses scaling for linear tanks
• Uses strapping tables for non linear tanks
• Can perform conversions: English, metric, Celsius, Fahrenheit, mass/volume,
• Uses the American Petroleum Institute (www.API.org) DLLs for the most update and correct volume correction routines

• Several gross leak detection options or can interface to leak detection equipment

• Track tank usage over different time periods 
• Import AutoCAD drawings or digital pictures of Monitor to use on operator interface
• English or metric units
• Many different tank group views: top view, side view, two dimensional, three dimensional, properly scaled, digital picture, virtual
• Huge selection of real-world interfaces: serial, Ethernet, PLCs, Profibus, DH+, Modbus, analog, Hart, OPC, ActiveX, .NET controls, can write custom software drivers for proprietary interfaces
• Custom interfaces can be written using many different tools including Visual Studio. 

Global Line Equipment Machine Monitoring for Efficiency Capacity Utilization Defects Yield Down-Time Metrics Key Performance Indicators KPI Information System

• Can call into remote Monitors to inquiry about tank levels, alarms, usage, etc.  
• Several redundancy options

• Interfaces to the internet and other computers using all Microsoft technologies: remoting, Web Services, XML, Business Server, DCOM, ASP.NET, sockets, secure sockets, others
• Largest collection of database support with OLE DB Providers, ADO.NET, ADO, and ODBC
• You can access Monitors (with proper security permissions) around the world via computer, internet browser, or PDA. 

• "Virtual Monitors" -- allows users to define logical Monitors so that they can group different sets of tanks into one group to view those tanks as a set.  For example, create a group of all tanks at one site with raw material A.  All tanks used for blending product B.  All tanks in the southeast that hold product C.  All tanks in the southeast that hold raw materials to make product D. 

• Can communicate using most technologies: Ethernet, phone, cell phone, radio, microwave, satellite, laser, wireless, internet, modem and others. 
• Integrates into higher level ERP systems such as Oracle, SAP, Peoplesoft, and others
• Based on Microsoft .NET technology so that it is compatible with 90% of all available hardware and software
• Remote service and support available
• Statistics, charts, graphs, and advanced analysis tools provide expert, and different points of view for different types of users

On-line Information Systems

• On-line policies, procedures and checklists for operators
• On-line maintenance procedures, records and repair videos
• On-line safety information
• On-line process & instrumentation drawings (P&ID)
• Information can be either electronic based or printed when needed.
• Information can be sent to PDAs so that operators, engineers, and managers always have real-time information with them
• Follows Best Practices for Globalization and Localization

Automated Control of Loading & Unloading

• Different shapes and sizes: ships, rail cars, trucks, totes, drums, boxes, etc. 
• Different states: dry powders & solids, liquids, gases
• Different units: by weight, by volume, by pallets, drums, box, etc
• Can read and write bar codes and RF tags
• Relieve operators of monotonous tasks, predict when operation will be complete so operator can go on to other work and come back when finished. 

Optimized Control of Blending & Mixing

• Monitor and control temperature, level, pressure, flow

• Optimized mixing and blending based on a recipe system that can monitor raw material properties and alter recipes for improved blending results
• Advanced PID control allows you to respond quickly to large system changes but reduce wear and tear on equipment once the process settles back down. 
• Create custom recipes for each customer

• Temperature, vibration and acoustical monitoring, alarming and control
• Additive injection

Optimized control of Processes

• Control valves, pumps, agitators, reactors, mixers, boilers, adding of raw materials and other devices in your processes

• Works with all major flow meters, tank level sensors, analyzers, pumps, valves, PLCs, I/O, etc. 
• Redundant control for safe operation
• Detailed process information for mass balance analysis, time studies,  and process improvement
• List of current operations by time to completion.  Way of helping operators see what they need to do next and what they need to do in the future. 

Alarm Monitoring & Notification

• Alarming on high or low levels, leakage, flow rates, temperatures, pressures, pH, conductivity, % solids, or any other parameter
• Alarms can signal strobes, horns, Public Address (PA) system, cell phones, pagers, PDAs, send e-mail alerts
• Current alarm and system status can be viewed from, or sent to, anywhere in the world including computers, PDAs, cell phones, pagers

Reporting & Historical Data

• We can provide basic data on incoming shipments, outgoing shipments, quality, lot / batch tracking, etc. 
• We can provide detailed process information for maintenance  and process improvement

• Can be web based by putting data into a database and then using ASP.NET to serve data to Internet Explorer clients.  Customers with passwords can "serve themselves" to the data
• Data can be stored in almost any type of database
• Wireless networks send information to portable computers that operators carry with them

• History reports and logs of all activities -- can be written to CD-ROM or DVD for archival purposes
• Create your own reports using in any format: Microsoft Word, Excel, Adobe Acrobat PDF, databases, XML, text, etc. 
• Example reports are done in text (CSV) and Excel and are ready to print or save. 

Integrating Security

Software Security

• Can use standard Microsoft Windows security
• Additional levels / points of security can be added as necessary
• Can use SSL, IPSec, VPNs, and others for secure remote communications
• Uses standard firewalls, virus protection

Physical Security & Safety

• Integrates video cameras and audio into system so that console operators can see and hear what pumps, tanks, valves, etc are doing and sound like. 
• Integrates "dead man" technology
• Integrates biometric devices -- fingerprints, iris scanning, etc
• Integrates employee ID: badges, bar code, magnetic stripe, RF Tag
• Can require operator to walk around the plant
• Can require operator to interface to system every 15 minutes to indicate they are alert, awake, and not injured. 

Pricing

Monitor Master starts at $10,000 for a basic Monitor monitoring application, with source code and site license.  Additional sites and technologies are discounted.  Note that it would be impossible to provide all the functionality listed above for this low price.  Prices go up to millions of dollars for integrated global operations with all the functionality listed above. 

Monitor Master is a functioning product out-of-the-box, for simple systems.  You simply configure the databases and go.  Many customers start with this simple system and expand and customize it as they learn more about their operations.  For larger, more custom applications, Monitor Master serves as a template that gives you a huge head-start on your architecture, database, and object, design, development, and testing. 

Line Equipment Machine Monitoring for Efficiency Capacity Utilization Defects Yield Down-Time Metrics Key Performance Indicators KPI Management Software FAQs

• Why Source Code?
• Why Microsoft?
• Globalization & Localization
• What Custom Controls are Included?
• What other Automation Graphics and Controls can be purchased?
• What models, standards, and best practices do we use?
• This is much more complex or different than what I need?
• After the NASDAQ meltdown, who can you trust your career and business on?
• How do I connect this product to real-world analog boards, I/O, PLCs, etc.?
• HTS generic operations model -- how do this product fit into the "big picture"?
• What are the Customization & Support options?

• What is the Licensing?
• What is High Tech Service's Brief History