Efficient operations management – the WinCC Runtime functionality

Manufacturing processes are becoming more and more complex against a background of ever increasing quality requirements coupled with fast product changes and frequent modifications. To ensure the highest possible productivity at the same time, it has to be possible to make prompt, target-oriented decisions regarding process optimization at all levels of a company. This requires an integrated flow of information across all operating levels and locations.
SIMATIC WinCC provides you with high transparency and the basis for process optimization.  The intelligent use of information improves the processes in the company for a fast return on investment. This reduces costs, avoids waste, improves the utilization of production facilities and ultimately guarantees better efficiency and cost effectiveness for the company.

Ready for worldwide use

WinCC allows you to implement display languages in a simple and cost-effective manner. Thanks to UNICODE support, the display language can be changed at any time during operation. This is independent of the language set in the operating system. This means that it is possible to display multiple languages parallel to each other, such as message texts in European and Asian languages.
This makes commissioning considerably easier in international teams.

Integrated Monitoring Client

The WinCC/WebUX allows for flexible operator control and monitoring of plant processes via the Internet or an intranet, especially using mobile devices (tablet PCs or smartphones). All devices with HTML5-capable browser are supported.
ONE monitor client is available without additional charge with the installation of the basic system as WinCC/WebUX server.

High-performance data archiving

Historical process information is saved as WinCC process value archives in the integrated, high-performance SQL database.  512 archive tags are already licensed in the WinCC basic system; this number can be increased at any time through additive PowerPacks. The memory requirement is optimized through efficient algorithms and intelligent, loss-free compression functions such as the Swinging Door algorithm. To reduce the amount of data for long-term archiving, the data can be compressed even further. To do so, the maximum value, minimum value or (weighted) mean, the sum or the difference is calculated for adjustable periods of time (e.g. day, month, year) and saved in compression archives.

In addition to automatic archiving, it is possible to add values manually to the archive or to modify archive values later with the appropriate authorization. This is required, for example, for laboratory values in some industries. For reasons of traceability, these values are marked as "modified manually" and the process is documented with an operation message.
In addition to archiving on a WinCC server, additional central long-term archiving can be implemented with the SIMATIC Process Historian option..

Efficient analysis of process values (Trends)

Efficient controls are integrated into WinCC process pictures for the display of current or historical data.  Process values can be displayed as a table or analyzed using a trend display.
The display is either predefined or can be adjusted individually by the operator, if authorized. Numerous means of representation guarantee the best possible overview.
The freely configurable toolbar functions also provide the option of integrating project-specific functions.
f(x) trends, e.g. pressure/temperature, can also be displayed in addition to the time- and value-based representation.

In combination with the Ruler Controls, there is also the option of performing statistical calculations online without the need for programming. The relevant statistics – maximum and minimum value, average value, (weighted) mean, integral and total – are displayed without delay  for a time range selected in the Trend Control..

Efficient analysis of messages

The messages are displayed on the screen via the freely configurable WinCC Alarm Control. Here, the display of the message information can be adapted precisely to the requirements of the operator. The settings made can be saved in user-specific or global templates.
WinCC Alarm Control for the display of current/historical messages based on the contents of the individual message blocks can be filtered, selected and sorted, for example chronologically, by priority or by fault location, in the display. The contents can then be exported directly as CSV file or printed out as report. A freely definable toolbar function also offers a maximum degree of flexibility. For examples, project-specific functions can be integrated. To maintain an overview when there is a large numbers of incoming messages, unimportant operating messages can be suppressed from the screen display via an alarm hiding function. The hidden messages are then archived in the background.

Numerous integrated statistics functions allow a comprehensive analysis of process states. The message hit list shows how long certain messages were pending on average and in total (message duration) and similarly the average and the total acknowledgment time. Of course, the messages can be filtered here by relevant events, message locations and time intervals. This indicates quickly where critical points and bottlenecks in the production are located. To sort the messages in the message display for an evaluation, you can simply select the column heading and the required sorting criterion (for example, "Frequency, descending").

Efficient process diagnostics

Integrated process diagnostics is available in connection with S7-1200/1500 controllers as of WinCC V7.4 and higher. It shows diagnostic information of  all connected S7-1200/1500 contrllers without further configuration efforts.

For existing solutions based on S7-300/400 controllers, WinCC/ProAgent enables targeted process diagnostics for machines and plants.

Efficient Web-based reporting

The SIMATIC Information Server offers web-based access to data from production and the SIMATIC Process Historian; it is used at all levels of the automation pyramid.

Efficient analysis of production processes

The WinCC/PerformanceMonitor enables you to analyze and optimize production based on individual performance indicators (e.g. OEE).
The PerformanceMonitor replaces the previous WinCC/DowntimeMonitor option

Efficient management of data records (recipes))

In WinCC/User Archives, associated data, such as recipes or production data, is collected in user archives with fixed data structure. During runtime, this data is exchanged simultaneously with the automation partners (e.g. a controller).

Traceability in production processes

WinCC/Audit is used to provide end-to-end traceability of operator activities in operation and to record project changes during the engineering phase by means of project versioning and audit trails. All change data is recorded in a tamper-proof database - the so-called Audit Trail - and displayed using the Audit Viewer. The use of WinCC/Audit helps machine manufacturers and plant operators to simultaneously reduce the expenditure for fulfilling the requirements according to 21 CFF Part 11 and EU 178/2002.

Efficient energy data management

Increasing energy costs worldwide are becoming a big challenge for companies – and thus also a key factor in a company's success and in safeguarding jobs.
Rising energy prices and an increased public awareness of environmental issues mean that effective energy management is contributing more and more to the success of companies and thus to safeguarding the continued existence of companies.

Improved energy controlling and the reduction of power costs are among the main challenges faced by companies. Industrial companies continue to battle against a lack of transparency in their infrastructure processes, against changing cost centers, heterogeneous system environments and a costly power reporting.

Calendar- and event-based functionality

The two calendar options expand WinCC with calendar-based functionality.  Joint calendar control is hereby used to plan times or validity periods.
Time-linked actions can be triggered with the WinCC/Calendar Scheduler.
The WinCC/EventNotifier sends notifications depending on the occurrence of certain events in the WinCC message system.