The Secret Ingredient in Operational Data and Technology · digital transformation journey? A....
Transcript of The Secret Ingredient in Operational Data and Technology · digital transformation journey? A....
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The Secret Ingredient in Operational Data and Technology
Kevin GenevaSenior Technical Advisor, OSIsoft
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Kevin Geneva• OSIsoft since 2011 in Philadelphia, PA• Mechanical Engineering from Penn State University• Technical Support, Field Service, PreSales Support,
and Product Management
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Polling Question 1…Where is your company in their
digital transformation journey?A. Considering options, but have not started
B. Don’t know, unsure
C. Fully on board, have processes in place for the journey
D. Have a pilot in place, evaluating
E. Have an ongoing successful project in place, and looking to do more
F. Nowhere, done nothing
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Polling Question 1…Where is your company in their
digital transformation journey?
11%
11%
44%
11%
22%
Considering options,but have not started
Don't know, unsure
Fully on board, haveprocesses in place forthe journey
Have a pilot in place,evaluating
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1250 Registered Attendees98 Customer Presentations24 Partner BoothsDay 2 – Industry Day
Food and Beverage StatusAvebe – Transformation to a data-driven organizationActemium – Mobile App powered by NFC and the OSIsoft PI SystemLonza’s PIVOT – Productivity Improvements via Operations Technology
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In the Pressure Cooker
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Margin Pressure
Changing Consumer Demands
Product Quality and Food Safety
Cost of Capital
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Maintenance means more to Food and Beverage
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Point Solution < Data Infrastructure
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How can a data infrastructure solve this?
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Quality System Integration with
Notifications
Edge Data Collection for
Vibration
OEE – Bad Actors Report
Condition-Based Maintenance
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Empower People to Drive Results
We believe that
people with data will
transform their world
Transform data into decision ready information
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Polling Question 2…What are the business problems that you
are looking to address with operational data technology?
A. Process Productivity
B. Quality/Safety
C. Energy Efficiency
D. Asset Health
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Polling Question 2…What are the business problems that you
are looking to address with operational data technology?
42%
0%
33%
25%
Process Productivity
Quality/Safety
Energy Efficiency
Asset Health
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• - Chemical Engineering Background
• - Since August 2018 @ MIT
• - Application contact / Adminfor the PI System & TrendMiner
Manager Manufacturing IT
Jan Spijkerman
Engineer Manufacturing IT
Justin Lambeck
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www.avebe.com
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We extract everything to be had
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Market - Food Ingredient Solanic
• Potato protein• Vegetable proteins• Non-allergenic, free of GM
materials, clean label, gluten-free• Very high nutritional value• Vegetarian, vegan, kosher & halal,
sustainable
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OEE - production line status dashboard
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TrendMiner in practice: Coagulation
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Problem StatementReactor shuts down once or twice for every CIP (Cleaning In Place) 30 times per year restart
ApproachUse TrendMiner to look for stable and unstable start-ups& Compare these periods
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TrendMiner in practice: Coagulation
Issue:
Valve opened to
fast
Solution:
changing ramping in
process automation
Searching similar situations and compare
good and bad events.
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TrendMiner in practice: Coagulation
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Reduction of 30 downtime periods per year.
Business impact
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RESULTSCHALLENGE SOLUTION
The technology storm is developing
Avebe developed an operations strategy “Avebe Factory4.0”
Strategic focus on getting value out of data
• Main goal Factory4.0: Transforming Avebe with data
• OSIsoft Enterprise Agreement
• PI System as strategic platform• TrendMiner Corporate Explorer
Program• Reduction of 30 downtimes per
year• Enhanced operational awareness
• More and more technologies coming available on the market
• Additional challenges with an ageing workforce: ~20% will retire within 5 years
Transformation to a data-driven organization
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Increase asset uptime
Reduce give-away (more water and less protein & starch in product)
Reduce starch, protein & fiber content in waste water
Reduce re-work
Optimize usage of chemicals
Strengthen operational optimization capabilities
Improve data capturing & data visibility across departments
Improve situational awareness regarding energy, CO2 & water consumption across departments
Expand energy mgmt. capabilities
Integrated system for production-, quality- & release-related data
Quality aspects in OEE
In-process quality prediction
Loss Prevention &Asset Health Process Productivity Energy Efficiency &
Water Usage Quality Mgmt.
Opportunities for Avebe
Capability & knowledge sharing
Enable resources by leveraging modern tools appropriately
Talent Acquisition & Retention
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Laurens Marijns
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International MES/MOM Coordinator for Actemium
Mobile App powered by NFC and the OSIsoft PI System
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• F&B represents a Top 3 industrial segment
• Global company• 21,000 employees• OSIsoft Partner
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Actemium
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Business Challenge
Improve manual data collection
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Solution
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RESULTSCHALLENGE SOLUTION
Manual CCP’s with NFC
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Manual Data Collection needed to be improved
Using cell phones, NFC tags, ID Badges, and the PI System Actemium built a solution
Easy to use, integrated app that suits the customers needs
• Modern, available technology• Proven technologies
• Built quickly and efficiently• Insight and tracking into CCP’s• Actionable, real-time information
• Plant Visibility• Compliance• Audit Trail
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Isabelle Lacaille
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Data Infrastructure Engineer with Lonza
PIVOT – Productivity Improvements via Operations Technology
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Lonza
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Red Carpet Incubation Program (RCIP)
Collaboration between OSIsoft and Microsoft• Addresses Industrial IoT Challenges• Jumpstart a data science initiative• Provide better operational insight
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• Increase in reaction time near the end of 2016
• Root cause: removed trays in distillation column never replaced
• No production disruption, coincided with start-up of second reactor system
Specialty Ingredients | Isabelle Lacaille | 18 September 2019
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RCIP OutcomesDiscovered optimization potential
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Post - RCIP
• Assets, Events, and Data modeled in the PI System• Hired Master’s student for data science• Continued to find opportunities in their plant• Infrastructure Tools: PI Vision, SEEQ, PowerBI, and
Unscrambler
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Accelerating Process Optimization ProjectsOpportunity #1: Optimize temperature increase during reaction
Data mining revealed golden batches with different temperature profile
High temperature causes evaporation of reactant, leading to slower reaction
Potential capacity increase of 15-18%
TemperatureTemperature Golden BatchHot Oil Flowrate
PressurePressure Golden BatchReactant Flowrate
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Accelerating Process Optimization ProjectsOpportunity #2: Optimize timing of reactant dosing
Data mining revealed golden batches with different pressure profile, correlating with reactant
Precise timing of reactant dosage decreases the occurrence of side-reactions
Potential capacity increase of 16-20%
TemperatureTemperature Golden Batch
PressurePressure Golden Batch
Reactant flowrateUnit Operation
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RESULTSCHALLENGE SOLUTION
Lonza’s PIVOT
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Lonza wanted to improve its productivity
Leverage people, process, and data collaboratively
Improvements identified with greater operational awareness
• Data contextualization• Reduce data preparation time to a
minimum• Process and data science experts
• Temperature optimization -Capacity increase of 15-18%
• Reactant dosing optimization -Capacity increase of 16-20%
• Identifying bottlenecks
• Plant Visibility• Unknown root causes of batch
variance• Identifying opportunities
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Process Productivity Quality Tracking Energy Efficiency Asset Health
Customer Use Cases: Summary
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Change overs
Distributed Supply Chains
Batch Management
Operational Agility
Regulatory Compliance
CMA and CPP influence
QMS /Corrective ActionPredicted Quality
Manage environmental impact
Sustainability initiatives
Reduce Utility Consumption
Overall Equipment Effectiveness
CMS Integration with real-time data
Condition based and predictive maintenance
Process Productivity Quality/Safety Energy Efficiency Asset Health
Business Outcomes Enabled by The PI System
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Contact information
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Kevin Geneva• OSIsoft, Philadelphia• [email protected]
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