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From Data to Action: How Decisions Are Made at AGC
Bradley Willson
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Agenda
• Who is AGC and what do they do?
• How did AGC use the PI System in the past?
• How does AGC use the PI System now?
• What are the next steps in the evolution?
• Questions
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Who is AGC Glass
North America
• One of the largest manufacturers of glass
• +4,300 employees
• PI user since ‘96
World Wide
• World’s leading power in flat glass
• +50,000 employees
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The Tools That We Use
Prior 2018• PI ProcessBook
• PI DataLink
• PI Manual Logger
Today• Migrating to PI Vision
• Building Asset Framework
• Creating Notifications
• Developing Analyses
• Integrated our ERP system into PI Vision
• Rolling out PI AF and PI Vision to other sites
Data Historian Data Infrastructure
1996 2018 Today
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AGC’s PI System Architecture
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IT versus OT
Prior 2018• Two separate
networks
Today
• The lines are blurry
• Share data in both directions
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PI Vision
PI DAPI DA PI DA
PI AFPI AF PI AF
PI Vision Tableau
OPC OPC OPCOPCOPC OPC RDBMS RDBMS RDBMS
Spring HillGreenland Richmond
Cloud
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Glass Making 101
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How to Make Glass
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How Do We Use The Tools?
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Process Monitoring
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Process Monitoring
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Process Monitoring
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Process Monitoring
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Process Tuning
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1d
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Power Monitoring
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Power Monitoring
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New Tools
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E-mail Notifications
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Production Reporting – PI Vision
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Production Reporting - DataLink
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Furnace Emissions Monitoring
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Troubleshooting
Melter Backwall
• Noticed increase of block temperature
• Trace events back to start
• Verify countermeasures
• 7 year trend
• 100°C span • Possible 2 week downtime
• ~$2M + materials/labor
50
150
7Y
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Troubleshooting
Coater Pressures
• Unable to maintain vacuum pressure
• Typical is 10E-6 mbar
• Sections only 10E-3 mbar
• Operator adjusting valves to pinpoint problem • ~$2,000 per hour
• Found issue faster
8E-3
0
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ERP System - Shop Floor Visualization
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ERP System - Shop Floor Visualization
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ERP System – Historical Data
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ERP System – Integration
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ERP System – Integration
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What’s Next?
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• Explore additional tools• Event Frames
• Analyses
• Continue developing PI Vision screens
• Rolling-Out to Other Facilities• How do we standardize?
• Not all furnaces are created equally
• Machine Learning using AWS and Tableau
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CHALLENGES SOLUTION BENEFITS
Now we know when a piece of equipment is down
earlier. This allows us the machine before it turns into a
major catastrophe.-AGC Greenland Maintenance Team
Reducing / Preventing Downtime
▪ Large facility with numerous machines
▪ Hard for operators to monitor everything
▪ Provide automated notifications to maintenance personnel
▪ Maintenance personnel are notified immediately when there is a problem
▪ Expanded SOW to include preventative notifications as well
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Speaker Contact Information
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• Bradley Willson
• Electrical Engineer
• AGC Glass North America
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