Transcript Reaching Across Boundaries
Reaching across boundaries, collaboration, Web Parts, and Notifications
Jim Cummins
Manager: Process Information 1 Empowering Business in Real Time. © Copyright 2009, OSIsoft Inc. All rights Reserved.
SMI: Sharing Information World Wide
“Specialty Minerals has a very dispersed work force with small facilities located around the world. Consolidating and surfacing production information is essential for daily management. Web Parts is a tool that integrates well with our web based communications. “
2 Customer Business Challenge • Collect accurate process information from small facilities located globally. • Provide a single source for viewing many locations and processes to employees in non centralized locations. • Communicate requirements to suppliers for automated deliveries.
Empowering Business in Real Time. Solution • Implemented a single PI server with interfaces to manufacturing facilities world wide.
• Implemented MS SharePoint with PI web parts to expose process information.
• Implemented notifications tied to inventory to Email suppliers.
Customer Results / Benefits • Dashboards and process analysis are driving continuous improvement ; lowering product costs improving performance. • Integration of information from multiple data sources.
• Timely, reliable, communication for material suppliers. © Copyright 2009, OSIsoft Inc. All rights Reserved.
3
Specialty Minerals
Synthetic Calcium Carbonate Facilities: 53 located globally Employees: 3 to 15 per location Symbiotic relationship with paper mill
Paper Mill Paper Machine PCC Slurry PCC Plant Gas H 2 0 Power Waste MTI Proprietary Technology Lime Source Chemical Sources Local Labor
Empowering Business in Real Time. © Copyright 2009, OSIsoft Inc. All rights Reserved.
4
Facility Design
• Facilities are highly automated using Siemens PCS7 DCS systems.
• Plants are or can be operated by a single individual or in many cases unmanned for periods of time. • Plants will run continuously 24X7 as needed to meet mill demand.
• Product is delivered to host mill by pipe line.
• Off site customers are supported with truck deliveries. Empowering Business in Real Time. © Copyright 2009, OSIsoft Inc. All rights Reserved.
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Our History with OSIsoft
• • • • • PI server was installed in Easton PA. data center in 2007. Data interfaces were installed at 8 facilities replacing local data Historians. Additional facilities were added in 2007 and 2008 including locations in Europe, Africa, South America, and Asia. PI ACE was added to populate batch tables in SQL Server. MS SharePoint Server was deployed with PI Web parts to expose process data on the secure company network. PI to PI interface has been used to link directly with the customer.
PI Notifications has been used to communicate inventory levels to raw material suppliers.
Empowering Business in Real Time. © Copyright 2009, OSIsoft Inc. All rights Reserved.
Interface and data collections
• Each of the facilities use a PI OPC interface installed on the Siemens PCS7 process control system operator interface computer.
• Process data is continuously streamed to the central server. Data is buffered at the plant in the event of a connectivity loss. • PI Batch and PI ACE are used to create batch records in SQL Server. 6 Empowering Business in Real Time. © Copyright 2009, OSIsoft Inc. All rights Reserved.
Challenge
Business processes needed to be stream lined.
Data quality, Timeliness, Labor, results distribution.
Collect Data • Operator required • Paper • Excel • Email Consolidation • Administration • Excel Spreadsheets • File Share or Email Reporting • Distribution • Customization • Interpretation • Email Days or weeks to complete 7 Empowering Business in Real Time. © Copyright 2009, OSIsoft Inc. All rights Reserved.
Challenge: Time to collect and Quality of data
Collecting information from each plant required many forms and manual data collection 8 Empowering Business in Real Time. © Copyright 2009, OSIsoft Inc. All rights Reserved.
Challenge Data consolidation and Analysis
10 Empowering Business in Real Time. © Copyright 2009, OSIsoft Inc. All rights Reserved.
Challenge data storage, access, and reporting
11 Empowering Business in Real Time. © Copyright 2009, OSIsoft Inc. All rights Reserved.
Challenge
Business processes needed to be stream lined.
Data quality, Timeliness, Labor, results distribution.
Collect Data • Operator required • Paper • Excel • Email Consolidation • Administration • Excel Spreadsheets • File Share or Email Reporting • Distribution • Customization • Interpretation • Email Days or weeks to complete 12 Empowering Business in Real Time. © Copyright 2009, OSIsoft Inc. All rights Reserved.
Solution
Business processes needed to be stream lined.
Data quality, Timeliness, Labor, and Reporting .
Collect Data • PI OPC Interface Consolidation • PI Server • ACE • SQL Server Reporting • PI WebParts • Notification • SharePoint Real Time 13 Empowering Business in Real Time. © Copyright 2009, OSIsoft Inc. All rights Reserved.
The Solution: Data Collection
• Install PI Server in Easton PA with interface to all facilities.
• Collect process data for each plant using PI OPC Interface • Implement PIBaGen (PI Batch Generator) • Utilize PI Process Book and Data Link
One Source for process information One version of the truth
14 Empowering Business in Real Time. © Copyright 2009, OSIsoft Inc. All rights Reserved.
The Solution: Consolidation
• Collect process data for each plant on one server.
• Implement ACE Server.
to create Batch Records in SQL • Plant information Roll up capabilities
One Source for process information.
One version of the truth.
15 Empowering Business in Real Time. © Copyright 2009, OSIsoft Inc. All rights Reserved.
The Solution: Reporting
• Expose summary information using MS SharePoint • PI Web Parts for quick summary of process information • PI Notifications for supplier communication
One Source for process information.
One version of the truth.
16 Empowering Business in Real Time. © Copyright 2009, OSIsoft Inc. All rights Reserved.
Solution
Business processes needed to be stream lined.
Data quality, Timeliness, Labor, and Reporting .
Collect Data • PI OPC Interface Consolidation • ACE • SQL Server Reporting • PI WebParts • PI Notification • MS SharePoint Real Time 17 Empowering Business in Real Time. © Copyright 2009, OSIsoft Inc. All rights Reserved.
Connection to each facility
MTI Firewall
Content Collaboration ement Intranet / Extranet Electro nic Forms Business Intelligence Search PI Historian and web server
PI WebParts End user tools Plant Firewall Local Programming HMI OPC Interface Production network
SIMATIC S7 Typical Plant Configuration
Office network
Initial Setup
“Extensible Server design”
Company Wide Implementation Growth Controlling cost Expansion capability over time without losing past investment
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Significant steps to implementation
1. Initial deployment of PI
a.
b.
c.
d.
Install and manage PI server . Install and manage interface on each control system. Use PI client tools including data link and process book to involve end users. Show immediate benefits in data acquisition and analysis.
Listen for suggestions to improve analysis.
Empowering Business in Real Time. © Copyright 2009, OSIsoft Inc. All rights Reserved.
21
Significant steps to implementation
2. Add more value over time with each new application.
a.
b.
c.
d.
Install and manage PI Batch.
Install and manage PI ACE.
Install SQL Server. Configure your batch triggers and create batch records from continuous data.
e.
Involve end users. Show immediate benefits in data acquisition and analysis.
Empowering Business in Real Time. © Copyright 2009, OSIsoft Inc. All rights Reserved.
Significant steps to implementation
3. Add value with each new application
a.
b.
c.
d.
e.
Install and manage MS SharePoint .
Install PI Web Parts and Baseline .
Create and publish batch summaries using tree view, table views, Time, and batch view.
Create pages to show plant KPIs, production, and other related information.
Involve end users.
22 Empowering Business in Real Time. © Copyright 2009, OSIsoft Inc. All rights Reserved.
Significant steps to Benefits
4. Listen to end users and get them involved.
a.
b.
c.
Develop actionable web pages from web parts to support i nternal company operations, management, and reporting requirements.
Improve your relationship with customers by implementing a PI to PI interface to their PI system .
Communicate to suppliers using PI Notifications.
23 Empowering Business in Real Time. © Copyright 2009, OSIsoft Inc. All rights Reserved.
Benefits
One source of the truth + Improved accuracy + Faster recognition of opportunities + Informed decisions = Lower costs One source for information • Web based • Real time updates • Accurate • Automated Analysis • Faster recognition of opportunities • KPI • Report by Exception Informed Decisions • Lower cost • Improve profits 24 Empowering Business in Real Time. © Copyright 2009, OSIsoft Inc. All rights Reserved.
Benefits
• Reduced time to collect and collate data • • Removes one roadblock to unmanned operation Accurate and verifiable data • • Removes one roadblock to unmanned operation One source for process data • • Every one works off the same data source • Reduction in time spent validating information One version of the truth 25 Empowering Business in Real Time. © Copyright 2009, OSIsoft Inc. All rights Reserved.
Benefits
• Process metrics including OEE calculations • Data to measure KPIs • Real time access to information from anywhere • Export from web site to Excel for unique analysis using third party modeling software.
26 Empowering Business in Real Time. © Copyright 2009, OSIsoft Inc. All rights Reserved.
Supporting the Continuous Improvement Process
Identify Opportunity Collaboration Content ment Intranet / Extranet Business Intelligence Electron ic Forms Search PI Web Parts Feedback Collect Data Solution With WebParts Analysis
Current Challenges
• Migration from SharePoint 2003 to SharePoint 2007 • Building content at the rate it is requested.
28 Empowering Business in Real Time. © Copyright 2009, OSIsoft Inc. All rights Reserved.
SMI: Sharing Information World Wide
“Specialty Minerals has a very dispersed work force with small facilities located around the world. Consolidating and surfacing production information is essential for daily management. Web Parts is a tool that integrates well with our web based communications. “
29 Customer Business Challenge • Collect accurate process information from small facilities located globally. • Provide a single source for viewing many locations and processes to employees in non centralized locations. • Communicate requirements to suppliers for automated deliveries.
Empowering Business in Real Time. Solution • Implemented a single PI server with interfaces to manufacturing facilities world wide.
• Implemented MS SharePoint with PI web parts to expose process information.
• Implemented notifications tied to inventory to Email suppliers.
Customer Results / Benefits • Dashboards and process analysis are driving continuous improvement ; lowering product costs improving performance. • Integration of information from multiple data sources.
• Timely, reliable, communication for material suppliers. © Copyright 2009, OSIsoft Inc. All rights Reserved.
30 Empowering Business in Real Time. Jim Cummins Manager: Process Information Specialty Minerals Inc.
© Copyright 2009, OSIsoft Inc. All rights Reserved.