Kuschnerus page1 ; 2003-12-01 ARC Conference Orlando January 2004 What Kind of Automation do the...

Kuschnerus

page 1 ; 2003-12-01ARC Conference Orlando

January 2004www.bayertechnology.com

What Kind of Automation do the Chemical and Pharmaceutical

Industries Need?

Dr. Norbert KuschnerusSenior Vice President, Bayer Technology Services

President, NAMUR

Kuschnerus



Bayer Technology Services – Facts and Figures 2003:

Bayer Technology Services (BTS) is a company of Bayer Holding with:• 2.400 Employees worldwide, located in Leverkusen, Germany; Antwerp,

Belgium; Baytown, Texas; Mexico City; Belford Roxo (Rio de Janeiro), Brazil; and Shanghai,

• Sales of 690 million Euros annually,• A current portfolio of 70 products covering needs in process development,

engineering and construction management, automation, logistics, production unit optimization, production unit maintenance, energy management, as well as turn-key construction of production units and infrastructure

• BTS operates in five areas:– Life Science– Crop Science– Polymers– Chemicals– General Process Industries

Kuschnerus



What Kind of Automation do the Process Industries Want ?

• We do not want automation to “just operate the unit.”This is summed up by the comment of one unit superintendentabout the traditional automation as“CAS” System” (Colorful And Stupid).

• What does the customer really want?

• Our answer: “Operate the unit that is embedded in a worldwide,integrated group of production facilities

• at best utilization of assets,• at highest yields,• at lowest raw materials consumption,• at lowest energy consumption,• at lowest personnel costs,• with 100% safety, • at highest reliability• to produce in-spec products,• at lowest inventories,• ready to deliver at all times.”

• In One Word: Economically

Kuschnerus



Automation leads to enterprise-wide process optimization

IntegratedProduction Unit

Operation

Operation with Enterprise-Wide Supply

Chain Optimization

RealPotential

Spot Combined

Enterprise Perfo

rmance

Unit Operation

2-3 %

4-6 %% of Total Revenue

Achieve the real potential by including the entire production process

Kuschnerus



Total Automation in Process Industries

Production Planning, Materials Management, Warehouse Management, Quality Management

Enterprise Resource Planning (ERP), Advanced Planning Systems (APS)

Manufacturing Execution System (MES)

Information Exchange

Production Unit

Distributed Control Systems (DCS)

Instrumentation (I&E) On-Line Analysis

SupplyChain

Optimization

Logistics Logistics

Advanced Process Control

PerformanceMonitoring,

Training Simulator

Kuschnerus



Total Automation in Process Industries

Production Preparation

ProductionExecution

(Batch)

ProductionData

Analysis

Asset Management

SAP: Enterprise Resource Planning (ERP)

WMWarehouse

Management

Manufacturing Execution System


Technical Logistics

(MIMS)

LaboratoryAutomation

(LIMS)

Control Systems

Electrical & Instrumentation On-Line PAT Laboratory

MMMaterials

Management

QMQuality

Management

PP-PIProduction PlanningProcess Industries

PMPlant

Maintenance

PerformanceMonitoring

ProcessOptimization


APOAdvanced Planner

and Optimizer

Raw Materials Logistics

TrainingSimulator

Sales Products LogisticsProduction Unit

Kuschnerus



Total Automation

Production- preparation

Production-execution

(Batch)

Production-data-

analysis

Asset- management

SAP: Enterprise Ressource Planning (ERP)

WMWarehouse-Management


Information exchange

Technical logistics(MIMS)

Plant - Unit - Process - Laboratory

Laboratory-automation

(LIMS)

Control Systems

Electrical & Instrumentation PAT-online Inprocess-control

MMMaterial-

Management

QMQuality-

Management

PP-PIProduction Planning

Process Industry

PMPlant

Maintenance


Processoptimization


APOAdvanced Planner

and Optimizer

Raw material logistics Sales material logistics

We do not need the overall scope for a

specific project, but we need to understand

the overall scope to ensure smooth

development of further automation.

Kuschnerus



Traditional Automation in Process Industries


ProductionExecution

(Batch)

ProductionData

Analysis

Asset Management


WMWarehouse

Management



Technical Logistics

(MIMS)



(LIMS)

Control Systems

Electrical & Instrumentation On-Line PAT In-Process Control

MMMaterials

Management

QMQuality

Management


PMPlant

Maintenance


ProcessOptimization


APOAdvanced Planner

and Optimizer

Raw Materials Logistics Sales Products Logistics

TrainingSimulator

Kuschnerus



Examples of Advanced Automation TodayReal life in a chemical and pharmaceutical enterprise

• Process optimization

Example: Advanced process control

• Performance monitoring in a chemical production unit

• Use of training simulators in a chemical production unit

• Supply chain optimization for worldwide production in

the process industries

• Manufacturing execution in a crop protection multi-

purpose unit

Kuschnerus



Plant Optimization Example: Advanced Process Control


ProductionExecution

(Batch)

ProductionData

Analysis

Asset Management


WMWarehouse

Management



Technical Logistics

(MIMS)



(LIMS)

Control Systems


MMMaterials

Management

QMQuality

Management


PMPlant

Maintenance


ProcessOptimization


APOAdvanced Planner

and Optimizer

Raw Material Logistics Sales Products Logistics

TrainingSimulator

Kuschnerus



Improvement of Process Operation

•

FC

Dam

feed

2 AB48 % 4 AB50% 6 AB

99% 6 AB

1% 4 AB

Q

On-Line NIR Analyzer

Example: Isomer Separation

Savings: > 1 Million € annually

After:• Product specification is observed on-line through

modern analyzer technology (NIR)• Completely automated process for in-spec

production• Reduced number of manual analyses (personnel)• Reduced energy consumption • Increased availability through faster load changes • Less off-spec production• Reduced raw materials consumption

• ROI of plant optimization: < 6 months

Before:• Isomer separation: Analysis in a traditional, off-

line laboratory (4-hour delay) • Quality assurance by excessive compliance with

product specifications

PCS

Improvement of Process Operation• Basis for OpX • Consists of

• Improved instrumentation• On-line analysis• Process modelling• Integration in DCS

Kuschnerus



Process Performance Monitoring


ProductionExecution

(Batch)

ProductionData

Analysis

Asset Management


WMWarehouse

Management



Technical Logistics

(MIMS)



(LIMS)

Control Systems

In-Process Control

MMMaterials

Management

QMQuality

Management

PP - PIProduction PlanningProcess Industries

PMPlant

Maintenance


ProcessOptimization


APOAdvanced Planner

and Optimizer


TrainingSimulator

Electrical & Instrumentation On-Line PAT

Kuschnerus



Process Performance Monitoring

Costs / Benefits (three-year experience from 40 projects)• Project Costs: 100,000 to 1 Million €• Project time requirement: 6 - 12 months• Energy reduction: Up to 10 %• Yield increase: Up to 10 %• Forecast of equipment problems: Up to 14 days within

a few hours margin of accuracy• ROI of plant optimization: < 6 months

Process Performance Indicators:• Operating Conditions, such as

•Energy Consumption•Raw Materials Consumption•Yield

• Asset Conditions, such as •Plugging and Fowling Forecast•Corrosion Forecast•Sensor Signal Reliability•Column Efficiency

Visualization, e.g. via Internet or Intranet

Process Performance Monitoring• Basis for OpX • Consists of

• Instrumentation Improvement• On-Line Analysis• Process Data Acquisition and Evaluation• Process Model• Visualization

Process performance monitoring is applied, when we cannot close the loop for process operation improvement

Kuschnerus



Training Simulator - Chemical Plants


ProductionExecution

(Batch)

ProductionData

Analysis

Asset Management


WMWarehouse

Management



Technical Logistics

(MIMS)



(LIMS)

Control Systems


MMMaterials

Management

QMQuality

Management


PMPlant

Maintenance


ProcessOptimization


APOAdvanced Planner

and Optimizer


TrainingSimulator

Kuschnerus



• Unit operator training • Plant scenario training: load changes and typical

malfunctions • Automation software tests

• Development of a dynamic model of the entire unit • Plant model link-up to an emulated DCS

• More highly skilled unit operators before startup• Improved automation software• Reduced commissioning time• Cost: 300,000 € - 700,000 € per unit• Savings. 50 % of startup costs• Avoidance of operational errors – savings in one case:

– 3 - 30 days of lost production– 100,000 - 1 million € maintenance costs

New UnitDynamic

Unit Model

Emulated ProcessControl System

OperatorWork Station

Visualizationof Real Unit

Training Simulator

Training Simulator - Chemical PlantsObjective

Action

Results

Kuschnerus



Supply Chain Optimization in Process Industries


ProductionExecution

(Batch)

ProductionData

Analysis

Asset Management


WMWarehouse

Management



Technical Logistics

(MIMS)



(LIMS)

Control Systems


MMMaterials

Management

QMQuality

Management


PMPlant

Maintenance


ProcessOptimization


APOAdvanced Planner

and Optimizer


TrainingSimulator

Kuschnerus



Supply Chain Optimization in Pharmaceutical Production Units

Active Ingredient Production

Active Ingredient Production

ShippingShipping

Formulation Capsules 20767 Tabletting

Formulation Capsules 20767 Tabletting

Packaging20747 Solida

Packaging20747 Solida

20771 20771ShippingShipping

Leverkusen: Formulierung & Verpackung

20771Formulation 20737 Parenteralia

Formulation 20737 Parenteralia

Formulation 20767 Tabletting.

Formulation 20767 Tabletting.

Pacckaging20743 Parenteralia

Pacckaging20743 Parenteralia

ShippingUSA / Japan

ShippingUSA / Japan

Micronization Micronization

MillingMilling

FormulationFormulation PackagingPackaging PackagingPackaging

20771

21926

21890

• Analysis of the interrelationships between demand, service level, production capacities (units and personnel), and inventory

• Evaluation of lot sizes and emergency inventories as to feasibility and plausibility

• Optimization and reduction of inventories along the supply chain

• Visualization, risk assessment, and debottlenecking, particularly in cases of multi-

layered production processes

• Normally:

• Project costs: 100,000 to 3 million €

• Return on investment: about 1 year

Leverkusen: Formulation and Packaging

Kuschnerus



Integrated System:Crop Protection Products – Multi-Purpose Plant


ProductionExecution

(Batch)

ProductionData

Analysis

Asset Management


WMWarehouse

Management



Technical Logistics

(MIMS)



(LIMS)

Control Systems


MMMaterials

Management

QMQuality

Management


PMPlant

Maintenance


ProcessOptimization


APOAdvanced Planner

and Optimizer


TrainingSimulator

Kuschnerus



Crop Protection Products – Multi-Purpose Plant• Pilot plant and production unit for crop protection

products• Total investment : 10 million €• Cost of MES, logistic systems and SCO: 5 million €• Highly complex production structure• Possibility of linking more than 200 unit modules• Possibility of combining up to 40 unit modules for

production campaigns of 3 - 5 months duration

•Personnel Reduction•Increase of Asset Utilization• Inventory Reduction• Process Improvement Through Electronic Batch Analysis• Avoidance of Raw Materials Mix - Ups• Savings: Unknown, but not operable without the

improvementsTransfering 50,000 data/month

Planning (Pilot) Batch

Generating Basic Recipe

CompletingBasic Recipe

DisposingMaterials

OrderingRaw Materiasl

DeterminingSupplies

Approving Batch / Trail

ForecastingSupplies

Documenting

Pilot) Batch

Approval;Generating

Control Recipe

ArchivingDocuments

AccountingProduction

Order

Pro

cess

Ord

er,

Mat

eria

l Bin

Dat

a

Pro

duct

ion

Dat

a

Pla

nnin

g Rec

ipe

Executing Control Recipe, identifying

Materials

Batch Flexible / PCS7

SAP R/3SAP APO

Mat

eria

ls

Mas

ter

Dat

a

Kuschnerus



Trends We See• DCS is becoming a basic commodity in the process industries,

– but its operation is still overloaded with information.– Much work still remains to be done to make HMI more production-friendly.

• Enterprise Resource Planning is becoming a standard,– but a lean and integrated information flow requires a lot of manual

procedures or excellent and sophisticated engineering. • Advanced manufacturing solutions and supply chain optimization

are the keys to success in coming years – Manufacturing Execution Systems– Logistic Systems– Advanced Process Control– Process Driven On-Line Analysis– Performance Monitoring– Operator Training Simulators– Supply Chain Optimization

are the real benefit of production process optimization with cost savings increasing up to 10% of the total revenue - However, they need the solid basis of I&E; DCS and ERP

Kuschnerus



What is Required from the Vendor?

Open Systems Each component must be able to communicate with any other component. “We want to have a full competition in price and technology”

(Jim Caie, GM, ARC - Orlando February 2003). We don’t think, that one single automation manufacturer can supply all required

components and the best technologies for complete solutions at the best price world–wide.

Easy to Use Systems to save engineering costs and ease operation

Modular HW and SW components Innovation cycles adjusted to the lifetime of the production units Technology must concentrate more on operational needs

Most sensors offer solutions for what is easy to measure and not what is needed. Traditional HMI overloads the operator with unnecessary information,

but does not immediately show what the operator really needs. Who is really taking care of asset management? Where is the entire information he

needs? Alarms must lead to the real cause

Alarm cascades confuse the operator and are most dangerous.

Kuschnerus



Total Automation

Production- preparation

Production-execution

(Batch)

Production-data-

analysis

Asset- management

SAP: Enterprise Ressource Planning (ERP)

WMWarehouse-Management



Technical logistics(MIMS)


Laboratory-automation

(LIMS)

Control Systems

Electrical & Instrumentation PAT-online Inprocess-control

MMMaterial-

Management

QMQuality-

Management

PP-PIProduction Planning

Process Industry

PMPlant

Maintenance


Processoptimization


APOAdvanced Planner

and Optimizer

Raw material logistics Sales material logistics

Total automation requires • a few additional high-tech hardware components• a lot of additional, highly sophisticated engineering• a wealth of experience• a small additional investment

Total automation brings the benefits of production at• lower operating costs• lower energy and raw materials consumption• optimized asset utilization and material flow• optimized product quality• high return on investment

This is operational excellence.

Kuschnerus



Thank youThank you

Kuschnerus page1 ; 2003-12-01 ARC Conference Orlando January 2004 What Kind of Automation do the...

Documents

Transcript of Kuschnerus page1 ; 2003-12-01 ARC Conference Orlando January 2004 What Kind of Automation do the...