Transcript Slide 1

Tracking and Improving Asset
Utilisation with PI and RtDuet
OCEANIA
OCEANIA
OCEANIA
TECHNOLOGY
TECHNOLOGY
TECHNOLOGY
SEMINAR
SEMINAR
SEMINAR
2008
20082008
© 2008
© 2008
OSIsoft,
OSIsoft,
Inc. |Inc.
Company
| Company
Confidential
Confidential
1
Introduction



Presenter #1 Dave Rose
Title: Sr. Metallurgical Eng.
ADM Systems Engineering
OCEANIA TECHNOLOGY SEMINAR 2008



Presenter #2 Scott Cordwell
Title: Managing Director
Alliance Industrial Services
© 2008 OSIsoft, Inc. | Company Confidential
2
Agenda
•
•
•
•
•
•
Business Challenge
Solution Description
Benefits
Licensing
Current Client List
Future Plans
OCEANIA TECHNOLOGY SEMINAR 2008
© 2008 OSIsoft, Inc. | Company Confidential
3
Business Challenges
1. Improve the Return on Invested Capital through better
asset utilisation.
– Measuring Downtime is critical to improving asset
utilisation.
2. Implement a solution that works.
– Has to be simple, easy to use and easy to understand by
all.
3. Combine Utilisation and Enterprise Resource Planning
for seamless use.
– Sharing downtime information between RtDuet and ERP
systems allowing for one version of the truth. Downtime
accounting is done by RtDuet and then shared with 3rd
party applications.
OCEANIA TECHNOLOGY SEMINAR 2008
© 2008 OSIsoft, Inc. | Company Confidential
4
Business Challenge 1
4. Improve the accuracy of downtime accounting.
– Recording, classifying and understanding
downtime has not traditionally been a straight
forward activity. In many cases, the onerous task
of capturing downtime data is left to control room
staff, whose priority is to keep the plant
operational rather than performing data entry
duties.
– As a result, downtime data is incomplete or
inaccurate, and downtime tracking efforts are
often abandoned.
OCEANIA TECHNOLOGY SEMINAR 2008
© 2008 OSIsoft, Inc. | Company Confidential
5
Business Challenge 1
5. Automate downtime accounting.
– Automating Downtime Tracking is necessary to
improve asset utilisation .
OCEANIA TECHNOLOGY SEMINAR 2008
© 2008 OSIsoft, Inc. | Company Confidential
6
Business Challenge 2
6. Implementing the automated Downtime System
– Operators and Management are too busy. Need a
solution that saves time vs. adding work.
– This task can be seen as a “Bear” and dropped
from management priority even though ROI is
usually < 6 months.
OCEANIA TECHNOLOGY SEMINAR 2008
© 2008 OSIsoft, Inc. | Company Confidential
7
Solution Description
• Downtime Tracking System Requirements:
– Automatically and accurately capture downtime and lost
opportunity for sub areas and selected equipment
primarily through an automated means while allowing
for manual data entry as required
– Provide reliable and meaningful information by allowing
downtime events to be classified (e.g. planned /
unplanned, process / equipment, reasons, etc.) and
organized without excessive data entry effort by the
appropriate personnel, in a manner that is consistent
with work processes
OCEANIA TECHNOLOGY SEMINAR 2008
© 2008 OSIsoft, Inc. | Company Confidential
8
Solution Description
• Downtime Tracking System Requirements:
– Support root cause analysis by capturing and
providing event history with sufficient detail
– Allow plant personnel to expand the system by adding
new failure codes and triggers as the knowledge base
grows and the plant evolves
– Interface with CMMS, ERP’s, and other database
applications
– Minimize network traffic
– Minimize tag consumption
OCEANIA TECHNOLOGY SEMINAR 2008
© 2008 OSIsoft, Inc. | Company Confidential
9
Solution Description
OCEANIA TECHNOLOGY SEMINAR 2008
© 2008 OSIsoft, Inc. | Company Confidential
10
Solution Description
• A licensed software for Downtime Tracking
using your PI System.
• Supported by the OSIsoft Partnership
Program, Product Embedding and ISV
agreement.
OCEANIA TECHNOLOGY SEMINAR 2008
© 2008 OSIsoft, Inc. | Company Confidential
11
Solution Description
What is RtDuet ?
™







A bolt on downtime event tracking software suite for the PI
Data Historian.
Which automatically generates downtime events using your
PI tag values as triggers.
Distinguishes between Primary (Shutdown) and Secondary
(Loss of Rate or Quality) type events.
Allows your Operators to add reason codes to the downtime
events easily.
Delivers standard downtime reporting and synchronisation of
event data to external databases.
Makes collection of downtime data much more streamlined
and accurate than traditional manual systems.
Allows you to leverage your investment in PI Data to drive
improvement in your plant and processes.
OCEANIA TECHNOLOGY SEMINAR 2008
© 2008 OSIsoft, Inc. | Company Confidential
12
Solution Description
PI Module Database
Core Module (CM)
[PI-Ace Module]
SQL Database
Application Reporting Interface (ARI)
[Web Site/ActiveX Control]
(2000/2005/Express)
PI Data
Reporting Web Services
[Web Service]
PI-SDK
Configuration Toolset (CT)
[Windows Application]
Reason Tree Editor
[Windows Application]
PI Batch Database
Bidirectional Transfer Service
[Windows Service]
OCEANIA TECHNOLOGY SEMINAR 2008
© 2008 OSIsoft, Inc. | Company Confidential
13
Solution Description
IIS Web Server
Application Reporting Interface (ARI)
[Web Site/ActiveX Control]
Active Directory Security
· Maintenance / Admin
· Reports
· Operations
· Validation
Reporting Web Services
[Web Service]
SQL Database
(2000/2005/Express)
PI-SDK
PI Module Database
PI Data
PI Batch Database
ARI \ Web Services Features
· Standard and Custom Reports
· Web Based HMI
· 4 Levels of Security Access
· Audit Trail
· Manual Entry of Events
· Live Downtime Monitor
· Downtime Event Validation
· Downtime Event Split
· Multiple Event Assignment
· NEW! SQL based Reason Tree
· NEW! SQL based data cache
OCEANIA TECHNOLOGY SEMINAR 2008
© 2008 OSIsoft, Inc. | Company Confidential
14
Solution Description
Machine Centre 01
SQL Database / Reason Tree
SQL Database
(2000/2005/Express)
Bidirectional Transfer Service
[Windows Service]
PI Batch Database
BiDirectional Transfer Service Features
·
·
·
·
·
·
Syncs direct table records or fixed interval records to
SQL data cache.
Provides faster access to downtime records.
Provides high speed reports
Provides data for NEW RtDuet reporting web service
Allows for Business Logic transactions to 3rd party
applications.
Allows for easier custom interfaces and reports.
OCEANIA TECHNOLOGY SEMINAR 2008
© 2008 OSIsoft, Inc. | Company Confidential
15
Solution Description
Main Screen
– Provides Navigation
– ASP.NET
– Links:
• Operator or Management Views
• Manual Entry
• Validation
• Reports
OCEANIA TECHNOLOGY SEMINAR 2008
© 2008 OSIsoft, Inc. | Company Confidential
16
Solution Description
Event Monitor
– View events in real time and assign causes.
OCEANIA TECHNOLOGY SEMINAR 2008
© 2008 OSIsoft, Inc. | Company Confidential
17
Solution Description
Event Screen
– Assign Root Causes automatically or when convenient.
OCEANIA TECHNOLOGY SEMINAR 2008
© 2008 OSIsoft, Inc. | Company Confidential
18
Solution Description
Validation Screens
– Validate Automatic or Manual Reason Codes
OCEANIA TECHNOLOGY SEMINAR 2008
© 2008 OSIsoft, Inc. | Company Confidential
19
Solution Description
Reports
– Drill Down to location of cause
– WEB or PDF
OCEANIA TECHNOLOGY SEMINAR 2008
© 2008 OSIsoft, Inc. | Company Confidential
20
Solution Description
Reports
– Loss Type – Primary and Secondary events
– Drill Down to Root Cause by Equipment and Loss Type
– WEB or PDF
OCEANIA TECHNOLOGY SEMINAR 2008
© 2008 OSIsoft, Inc. | Company Confidential
21
Solution Description
Reports
– Available and Utilized Machine Time
– WEB or PDF
OCEANIA TECHNOLOGY SEMINAR 2008
© 2008 OSIsoft, Inc. | Company Confidential
22
Solution Description
Configuration
Toolset
– Easy to Use
– Make changes
on the fly
– Standardize
Downtime
terminology
OCEANIA TECHNOLOGY SEMINAR 2008
© 2008 OSIsoft, Inc. | Company Confidential
23
Solution Description – Primary Event
Machine Centre 1
Machine Centre 1
Primary Trigger 1
PI Tag 1
Digital State
PI Tag 1 = Stopped
Stopped
Running
Stopped
Running
Primary Event
Machine Centre 1
Run
Sec
Pri
Time
OCEANIA TECHNOLOGY SEMINAR 2008
© 2008 OSIsoft, Inc. | Company Confidential
24
Solution Description – Secondary Event
Machine Centre 1
Machine Centre 1
Secondary Trigger 1
PI Tag 1
RPM
PI Tag 1 < 200
168
420
Slowed
Running
Secondary Event
Machine Centre 1
Run
Sec
Pri
Time
OCEANIA TECHNOLOGY SEMINAR 2008
© 2008 OSIsoft, Inc. | Company Confidential
25
Benefits
• Large, fast ROI
– RtDuet provides real information to improve your
bottom line results.
OCEANIA TECHNOLOGY SEMINAR 2008
© 2008 OSIsoft, Inc. | Company Confidential
26
Benefits
Improve Resource Allocation
Downtime
hours
month
90
80
70
60
50
40
30
20
10
0
Bonding Sec
Crushers
Glue Section
Dryers
HVAC or Building
Services
Tailings
Instead of having plant resources focus on small problems, using
RtDuet you can accurately assign resources and target the top
causes of DT and areas for improvement and cost savings.
OCEANIA TECHNOLOGY SEMINAR 2008
© 2008 OSIsoft, Inc. | Company Confidential
27
Benefits
Eliminate Squeaky Wheel Syndrome
80
70
60
50
40
30
20
10
0
Oper
Maint
Prod
Raw Mat Quality
Testing
Quality Testing Dept. MAY BE THE “SQUEAKY WHEEL”, BUT NOT
THE BIGGEST PROBLEM
Using RtDuet you can accurately assign responsibility and solutions.
OCEANIA TECHNOLOGY SEMINAR 2008
© 2008 OSIsoft, Inc. | Company Confidential
28
Licensing Plans
• Individual Plants licensing by PI Tag Count
• Enterprise Licenses available for
Companies with multiple sites permitting all
sites to take advantage of the power of
RtDuet.
OCEANIA TECHNOLOGY SEMINAR 2008
© 2008 OSIsoft, Inc. | Company Confidential
29
Current Licenses
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
Atlantic Wallboard, Saint John NB
BHP Billiton, Ravensthorpe Mine, Australia
International Power, Hazelwood, South Australia
Irving Personal Care, Moncton, NB
JDI Sawmills, Saint John, NB
Lake Utopia Pulp & Paper, Lake Utopia NB
Michelin Tires, Granton, NS
Nyrstar, Clarksville, Tennessee, USA
Nyrstar, Port Pirie, South Australia
PanPac Forest Products, Napier, New Zealand
Wabush Mines, Wabush NL
Zinifex, Roseberry Mine, Tasmania
Zinifex, Century Mine, Lauren Hill, North Queensland, AUS
Zinifex, Karumba Port Facility, North Queensland, AUS
AUR Resources, Newfoundland, Canada
Portland Cement Company, CA, USA
OCEANIA TECHNOLOGY SEMINAR 2008
© 2008 OSIsoft, Inc. | Company Confidential
30
Future Plans
•
•
•
Plans to test with AF 2.0 prior to release
Continue Integration with ERP
–
Currently receiving work order information and sending
notifications back to CMMS
OEE Calculation Module – Fall 2008
–
Scheduled Plans will be linked with RtDuet to calculate “Planned”
OEE.
OCEANIA TECHNOLOGY SEMINAR 2008
© 2008 OSIsoft, Inc. | Company Confidential
31
Questions?
Thank you.
OCEANIA TECHNOLOGY SEMINAR 2008
© 2008 OSIsoft, Inc. | Company Confidential
32