© Copyright 2011 OSIsoft, LLC
Presented by
© Copyright 2011 OSIsoft, LLC
Using the PI System in
Manufacturing
Pasha Ahmad
Amman Regional Seminar
October 31, 2011
© Copyright 2011 OSIsoft, LLC
3
Agenda
• Information Transformed into Asset for Survival
• PI System Infrastructure Summary
• Putting the Infrastructure to Use
• Using PI System in Different Industries
• Examples, Case Studies, and Discussion
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4
Data, Information, and Intelligence
• Data
• Information
• Intelligence
• Information and Intelligence Converted into Assets
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PI System Infrastructure + Applications Transforms
Information into Asset
Present
View data, identify
problems, and take
corrective action
with familiar, easy-
to-use graphical
tools.
Analyze
Access real-time or
historical role-
based data for the
entire enterprise at
any time.
Connect
Collect data from
hundreds of
sources.
Manage
Gather and archive
large volumes of
data. Scale to meet
your growing
business needs.
BUSINESS
Interfaces Servers Analytics Visuals
Facilities
© Copyright 2011 OSIsoft, LLC
The Real Value is Manufacturing Intelligence
“Manufacturing Intelligence (MI), also known as Enterprise Manufacturing Intelligence (EMI), software delivers real-time information about manufacturing processes to help businesses optimize the performance of these processes as well as manufacturing yields. MI software gathers and analyzes production data, provides role-based visualization, and helps manufacturers reduce waste. The software also enables the improvement of manufacturing processes, identification of best practices, and the ability to respond to exceptions and events.”
Manufacturing Intelligence:
• Delivers real-time information about manufacturing processes
• Gathers and analyzes production data
• Provides role-based visualization
Delivered Value:
• Optimize process performance and manufacturing yields
• Reduce waste
• Improve manufacturing processes
• Identification of best practices
• Respond to exceptions and events
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Overcoming Logistical Challenges with
Collaborative Technologies
• Traditionally, computerized systems have been focused on automating calculations,
operations, and work flow processes.
• Automation is an effort to minimize the use of existing human resources.
• Emerging computer technologies are focused on ubiquitous access to integrated
information. Technologies like web-based portals, virtual presence, and business
intelligence tools enable collaboration, allowing organizations to address challenges in
new ways.
• Collaboration is an effort to maximize the use of existing human resources.
• Real-time information is essential to fuel the collaborative engine by enabling awareness
and supporting continuous improvement efforts.
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Overview
• Enabling Awareness: The Value of Real–Time
• Delivering Opportunity: The Need for Infrastructure
• Overcoming the Challenge: Performance Intelligence
• Collaborating to Improve: The Real-Time Infrastructure in Action
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Enabling Awareness
The Value of Real-Time
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Assessment of Condition
Electrocardiogram
• Statement of “goodness”
• Actionable
• Critical
The Value of Real Time
Forecast
World Cup
Scores
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Fuel flow spikes discovered costing $93,000 / year.
Wasted Fuel Gas
The Value of Real Time
Fundamental Principle
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TARGET FUEL
FLOW
Another Opportunity – Continuous Improvement
The Value of Real Time
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Capturing opportunities requires the right people.
The Challenge of Real Time
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Delivering Opportunity
The Need for Infrastructure
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Accessible by Expected Standards
• Interfacing with over 400 different automation sources
• Compliance with Industry Standards – OPC UA, PRODML, XML
• Query-based Access, OLEDB
• Integration with Microsoft Office Tools – Excel, VBA
• Integration with Microsoft and SAP Web Prortals
• Supports Application Development- OSIsoft vCampus
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Relational Data Real Time Data
Formulas User Defined
Asset elements derived from a common
template for each equipment type
Contextual for Information Integration
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Contextual for Users and Applications
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Overcoming the Challenge
Performance Intelligence
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Benchmarking
Performance
Against
Objectives
Articulation of
Performance
Rules
Accountability of
Manufacturing
Objectives
Collaboration Driven by Transparent Accountability
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Organizational Presentation of Real-time Opportunities
PI WebParts 2010 for Microsoft SharePoint 2007 or SAP Enterprise Portal
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Email with
links
relevant
information
Integration with
Virtual
Prescience
Technology
Event-based Notification of Real-time Opportunities
PI Notifications (PI System 2010)
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Democratized Business Intelligence
Delivered through a familiar environment
Integrated into business productivity infrastructure
Built on a trusted and extensible platform
Improving organizations by
providing business insights to
all employees leading to better,
faster, and more
relevant decisions
Microsoft BI Vision and Strategy
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Collaborating to Improve
The Real-Time Infrastructure in Action
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Enterprise Integration of
Operational Data from
Wind Farms John Mostek, O&M Engineer
John Deere Renewables
OSIsoft 2010 Users Conference
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Operating Commissioning Construction Operations Center
Project Locations
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Enterprise Management System
PI System is the foundation on which our EMS
is built, and is the basis for dashboards
monitored in our Operations Center
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Aggregation controls
(AF / MDB hierarchy)
Time controls
Dashboards
SharePoint portal environment on intranet, using PI WebParts
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Real-time Status Displays
PI ProcessBook rich client application
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Geospatial Context Customized code to overlay real-time PI System data in the Google Earth environment
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Production Forecasting
Web services with PI System data queries, served up in Business Objects using Flash
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Alarms and Notifications
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Benefits
• 77% improvement across our fleet in Energy Capture performance metric within first 6 months of PI System roll-out
• Top-line impact of Operational Awareness
• Data fit within a consistent Enterprise platform
• Use of templates / PI AF hierarchy structure = rapid integration of new project sites
• Leverages existing sources of Metadata
• Extensive library of off-the-shelf interfaces available from OSIsoft
• Future data sources become an easy fit
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• Integrated Water Management
Municipal, Industrial, Agricultural
Consumption
Smart
Meters
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Integrated Water Management
• Similar concept as power, but in water.
• AMI and Smart Water Meters in homes.
• Domestic Water management.
• 32 million meters by 2016.
• $16B industry by 2020.
• Trial Palm Desert, 17% lower consumption.
• City of Toronto, cut meter readers saves $33M.
• California cut 20% water use by 2020.
© Copyright 2011 OSIsoft, LLC
Future Earth 2025 Documentary:
– Dust storms: Las Vegas $120M removing turf
– Water Wars (Indus, Nile, Jordan River)
– Wild Fires: Victoria, OZ in 2009. In last 5 years, rainfall in California
dropped 48%
– Lake Mead dry by 2021, no water for Las Vegas, no power for LA
– Collaboration, Conservation and efficiency is imperative.
• Water Scarcity Consequences
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~30% Operating costs attributed to energy
3% USA National Energy Consumption
2 Gallons of Water / KWh consumed
Is This Sustainable?
Water / Energy Nexus
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1. Moulton Niguel
Business Issues:
Increasing Power Costs
Tightening Budgets
Critical Peak Pricing
>200 kW dynamic demand response pricing coming
Business Value:
Real-time power management
$$$ savings in reduced power costs
Participate in more demand response programs
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• Safe, Reliable, Efficient Ops
• Increase Pumping Efficiency
• Reduce Rates Beyond Time of Use (TOU)
• Minimize Demand Costs
• Optimize Rate Schedules
• Make Operators “Energy” Knowledgeable
• Maintain a “Continuous Improvement” Environment
• Make Energy Management a Business Process
Moulton Niguel Water – Energy Costs
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Real-time Energy Management 15% or $200,000+ Annual Energy Savings
© Copyright 2011 OSIsoft, LLC
2. Halifax Water
Business Issues: Water loss management
ILI = 9.0
$$$ lost due to water leakage
Reduce Capex and water consumption
Business Value:
Automatic real-time leakage detection
$$$ savings in reduced water loss
Integrated view of entire water system
Sustainability
325,000 residents served
© Copyright 2011 OSIsoft, LLC
Halifax’s Success Water service to 325,000 people.
$650,000 / yr savings by reducing water
leakage (DMA Night Flows).
2 million gallons / day saved
Quickly account for non-revenue water
Reduced ILI to 3.0
Data to validate back-charge to
contractors.
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“Sustainability, both sides of the meter.” Carl Yates, GM of HRWC
Real time water consumption dashboards for largest consumers
Halifax’s Success
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Center of Excellence for Enterprise Operations Advanced Water Management: SMART and Sustainable
Kinetic Energy Recovery Close Supplier Relations Ultra Pure Water
Treatment Efficiency
Heat Energy Recovery
Manufacturing Use Efficiency
Stewards of the Resource Waste Water Treatment
Lake Champlain
Vermont’s
Greatest
Water
Resource
Smarter water for
a smarter planet
Instrumented – Obtain and
collect real time data
Interconnected – Data analysis
and visualization
Intelligent – Analysis becomes
action, transform how we operate
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Center of Excellence for Enterprise Operations
SMART Waste Water Results
0
0.2
0.4
0.6
0.8
1
1.2
08/2
4/20
05
11/2
4/20
05
02/2
4/20
06
05/2
4/20
06
08/2
4/20
06
11/2
4/20
06
02/2
4/20
07
05/2
4/20
07
08/2
4/20
07
11/2
4/20
07
02/2
4/20
08
05/2
4/20
08
08/2
4/20
08
11/2
4/20
08
02/2
4/20
09
05/2
4/20
09
Phosphorous
2005-6 Avg
2007-current avg
NPDES Discharges
Waste Water Sludge
Manufacturing Capability Up 30% since 2000
(excluding 2009)
Phosphorus: - 48%
Fluoride: - 44%
TDS: - 54%
Water & Waste Water Chemical Usage
Disposal Cost: - $49K/yr
Generation: - 600K lbs/yr
Annual Costs: -$401K/yr
Reduction: - 2,162K lb/yr
Burlington Waste Water Management Goals
- Quality: Meet or exceed regulatory requirements
- Reliability: Zero manufacturing down time
- Cost: $450K/year reduction in annual cost
Units mg/l NPDES limit 1.2 mg/l
Phosphorus Discharge
© Copyright 2011 OSIsoft, LLC
Philosophy for OSIsoft PI System in J&J Pharma
• Get away from counting “tags”
• Collect all data (GMP & non-GMP)
– Process, Alarm & Events, Batch Events
• Deliver a consistent infrastructure globally
– no differentiation from Commercial to R&D
• Provide common visualisation (thick & thin clients)
– Consolidated data visualization for improved process monitoring and historical batch analysis
– Consolidated alarm reporting for building management, process control, laboratory equipment, utility systems, warehouse equipment…
• Targeted compliant reporting (RtReports)
– Autoclaves, washers (non-MES related!)
© Copyright 2011 OSIsoft, LLC
Enterprise Agreement – Current Scope
Malvern, PA
Radnor, PA
Springhouse, PA
Cork, IR
Leiden, NL
Gurabo, PR
Manati, PR
Beerse, BE
Geel, BE
Schaffhausen, CH
Latina, IT
Higi, India
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Enterprise Agreement - Delivering Value
• Get the data in the hands of the users
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Enterprise Agreement - Delivering Value
• Logistics – bulk solvent monitoring
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Enterprise Agreement - Delivering Value
• Utilities – AHU Airflows
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Enterprise Agreement - Delivering Value
• Alarm Monitoring & Paging
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Enterprise Agreement - Delivering Value
• Monitor Home Control Network (MCN)
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Enterprise Agreement - Delivering Value
• Compliant Reporting
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53
Process Overview of Cement Operations
© Copyright 2011 OSIsoft, LLC
A single data format for all plant data management, analysis and archival
Crusher
Preblending
Additives
Raw Mill
Blending Silos
Precalciner
Kiln Cooler
Additives Cement
Mill
Clinker
Silo
Cement
Silo
Quarry
Quarry Data Raw Mill Data Kiln/Cooler Data Cement Mill Data Raw Mix Data
Enterprise Data Lab Data
PI will give you value by
real-time improvements in
• Energy savings
• Emissions monitoring
• Process data
• Product quality data
• Maintenance scheduling
• KPI measurements
PI can connect all your
islands of information
• Process controls systems
• Lab analysis devices
• Motor control centers
• Vibration analysis devices
• Gas analysis systems
• Infrared camera systems
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Monitoring and Transforming into Intelligence
• Quarry Operations
• Crushing Operations
• Blending and Raw Material Grinding
• Preheat,
• Kilns
• Clinker Storage and Finish Grinding
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Key Performance Indicators
1. Inventory Utilization
2. Energy Consumption
3. Capacity
4. Quality Indicators
5. Fuel Consumption
6. Asset Utilization
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© Copyright 2011 OSIsoft, LLC
© Copyright 2011 OSIsoft, LLC
Dashboard of KPI’s for Each Plant Area
Operational Data Protected
“Cement producers need to develop their KPI operational and maintenance data, but be able to
share it with key support groups, this provides an important business benefits. Without the use of
the PI System, it would have taken them several months to gather and analyze the information.”
Customer Business Challenge Solution Customer Results / Benefits
• Providing key process indicators for
increased quality and production
• Closer monitoring of electrical and
fuel usage
• Developing long term historical
data for improved maintenance
• Implemented PI system to provide
connections to plant wide systems
• Provided focused view and data
analysis of MTC’s and emission
controls.
• Provides monitoring and analysis of
all equipment history
• Strong positive real-time composite
audit for all major plant areas
• Reduced energy costs and real-time
indicators for energy management
• Focused maintenance data to aid in
seeing problem areas before failures
occur
Process Monitoring
Real-time Web Access
Plan Execution \ Inventory Report
Equipment Health and Maintenance - Pemex
Control System Effectiveness
Multivariable Control Collaboration
Control System Effectiveness
Constraint Analysis
Data Reconciliation
Any Questions?
• Questions