Transcript How to prepare for the future? Why and how SABIC-EuroPetrochemicals is improving the current (ICT-) infrastructure for asset information Walter Jacobs Senior Advisor Plant.

How to prepare for the future?
Why and how SABIC-EuroPetrochemicals is improving the
current (ICT-) infrastructure for asset information
Walter Jacobs
Senior Advisor Plant Automation
SABIC-EuroPetrochemicals
April 11, 2005
Process Engineering Lifecycle Conference 2005
1
Presentation overview
1. What is Asset Information Management (AIM) about?
2. Why improve AIM?
3. AIM plan for SABIC-Geleen site
4. Asset Data Warehouse overview
5. Where are we today?
Process Engineering Lifecycle Conference 2005
2
Business Processes
Demolition
Primary
business process
Marketing
Research
Maintenance
Production
Purchasing
Construction
Secondary
business process
Engineering
Process
development
Process Engineering Lifecycle Conference 2005
3
Sales
Asset Information is created and
used in work processes:
• Operate Plant
• Asset utilization
• Improve Equipment Reliability
• Maintain Plant
• Turnaround Plant
• Large Capital Projects
• Small Projects
• …………………
Definition of AIM
•
Associated with a plant are large amounts of technical asset
information such as drawings, lists, indexes, data sheets, procedures
and instructions. This information is used and changed every day by
maintenance engineers, technologists, operators, mechanics,
purchasers, plant management, contactors, etc.
•
Asset Information Management (AIM) is the structured approach to:
– electronic information storage, disclosure and management.
– integration of this information in manufacturing work processes
throughout the asset lifecycle.
Process Engineering Lifecycle Conference 2005
4
Asset Information Management comprises 4 areas
(IT-) Systems
(computer applications,
databases, network
infrastructure)
activity 1
Information
Asset
Information
Management
(contents of: drawings,
instructions, classification
lists, process conditions, etc.)
Yes / No?
activity n
People
Procedures
(organization, skills,
attitude of people)
(work processes, workflows,
authorizations, rules)
Process Engineering Lifecycle Conference 2005
5
Vision
1. Managing Asset Information according to best practices is a
prerequisite to keep our License to Operate and to achieve
Manufacturing Excellence.
2. All SABIC personnel, and authorized 3-rd parties, involved in
manufacturing should have easy access to correct and up-todate plant asset information, and be able to process this
information through a simple desktop interface.
Process Engineering Lifecycle Conference 2005
6
The average AIM environment in a plant
Department
archive
Staff
archive
Bediening
instructies
Part
lists
Manual
procedures Data
sheets
P&I
week
rapporten
Risk
analysis
Sluit
procedures
Smeer
lijst
Work
Isometrics
procedures Classificatie Maand
rapporten
Storings
lijst
Revisie
analyse
keuringspl
Vaba’s
Calculations
Grond
Classifcatie
rapport
apparaten
Test
schema’s
lijst
DCS
rapporten
leidingen
Intools
Grond
documenten
Analyse
schema’s
Contracts
Klant
rapporten
Acceptatie
Storings
artikel
documenten
analyse
lijst
Piping
Instrument
Materiaal
list
index
attesten
Slangen
Cross
Training Hook-upsMocking
Spareparts
lijsten
reference
material
bird
Gereed
BM
list
lists
Dag
schaps
dossiers
Schakel rapporten
Project
Afdelings
lijsten
Project
instructies
Stof
info
documenten
Motoren
instructies
Mgt tools
bladen
lijsten
Klemmen
Opstellings
Inspection
lijst
Kabel
tekeningen
reports
Recepturen
lijst
PO
Steek
plannen
Appendage
Apparaten
schijven
Training
Meldings
lijsten
DSM
Equipm
lijsten
lijst
material
formulieren
Calc
AutoCad
list
Drawing
archive
OBS
Personal
archives
Maintenance
archive
Process Engineering Lifecycle Conference 2005
7
Main drivers to improve AIM
• Improve compliance towards “License to Operate”.
• Improve reliability and availability of information:
–
–
–
–
1 unique, consistent and up-to-date data source used by everybody.
overview of all information available and know where to find it.
faster access to accurate and relevant information.
controlled change of information (audit trail).
• Enable more efficient collaboration between plants, shared resource
departments, and external parties.
• Become more cost effective: 1 integrated and harmonized system i.o.
a multitude of different systems and tools.
• Create a more appealing and professional environment for personnel.
Process Engineering Lifecycle Conference 2005
8
AIM plan for SABIC-Geleen site
•
Implement a common Asset Data Warehouse (ADW) in all plants.
– Storage and disclosure of information
– Information management
– Integration with work processes
•
Take small steps, gain management and user acceptance first
before adding new capabilities.
•
Implement best practices for AIM.
•
Use ADW for new AIM applications.
•
For new capital projects, use ADW to store asset information.
•
Revise internal procedures concerning management and
responsibilities w.r.t. data and information  workflow.
Management of CHANGE!
Process Engineering Lifecycle Conference 2005
9
Some best practices for AIM
• Lifecycle of information (create, review, approve, publish) is governed
by a standardized Management of Change procedure.
• Ownership of information is assigned to function roles in plant.
• Version and status of asset information is controlled by IT tools.
• As much as possible information is stored as data i.o. documents.
Document
Data
Data
a document is a collection of data at
a specific point in time.
documents can always be retrieved
from data, but not vice versa.
Data
• Data are stored at one place only.
(if not possible, duplication is controlled automatically or procedurally)
• (Multidisciplinary) information is read-accessible to all relevant users.
Process Engineering Lifecycle Conference 2005
10
Process view
MoC
Small Projects
Document life-cycle
Change
Request
Mark-up
Approval
of
descriptio
n
Create
Value
Added
Project
“for review
package”
Approve
Review
Release/
Publish
Author
Archive
“for
construction
package”
Engineer
Approve
Review
Release/
Publish
Author
Archive
Approval
of
design
Construc
t
Approve
Review
Approval
for
Implemen
tation
Completi
on
“as built
package”
Release/
Publish
Author
Archive
Analyze
results
&
Verify
value
Process Engineering Lifecycle Conference 2005
ADW
11
Systems view: ‘as-is’ situation (2005)
Business Information Management
8-weken plan
Spare parts
Hulpstukken
Spaccs
ODG viv’s
ERP
(SAP)
Orderboek
Comprost
Asset Information Management
Onderdelenlijst
MatrixOne
Spaccs
Operational Information Management
Promis
Reference 2001 E-wacht
Inspect
WKT
boek
Mockingbird rollindex
Protecs
Aspen+
Aspen+
Tussenschema
Projecten
AFEX
NAK3
MDG
diversen
Spyro
Wijzigings
Compass
Plis Wachtboek Log
formulieren EDMS
Logsim
ldPE
Intools
Rolverdeling
AutoCad
Wijzigings
formulieren
MicroStation
Apparaten Log
NAK3
Instruct
MES
(Aspentech)
Dedicated
systems
DCS
(Honeywell, Emerson)
PLC’s (HIMA, Siemens) &
Field Equipment
plus many other applications and archives (electronic and paper)!
Process Engineering Lifecycle Conference 2005
12
Systems view: ‘to-be’ situation ( 2008)
Specific applications:
ARIA, Werkvergunningen, ...
Business Information Management
ERP
(SAP)
Asset Information
PEMS
Management
Operational Information Management
MES
(Aspentech)
ADW
(SAP)
Specific applic.:
Wachtboek, …
Protecs
DCS
(Honeywell, Emerson)
CAD/E
CBT
(Intools)
CAD/E
(Compass
(Logsim)
Train)
CAD/E
(Conval)
CAD/E
(AutoCad)
Process Engineering Lifecycle Conference 2005
Process
Engineering
(Aspen)
13
PLC’s
(HIMA, Siemens)
Monitoring
Systems
Functional view ADW
Profile management
WorkFlow management
 User / role definition
 CRUD Authorities
 Allocation of ownership for
data and documents
Data management
Plant
 Plant
Breakdown
Production Unit
Structure
Maintenance
Area
 Equipment
Process Unit
classifications
Equipment
Lines
Loops
 Object naming
 Data exchange
F1100
Appraisal
Preparation
Execution
 Workflow definition
 Notification, control and tracking
 Routing and controlled info. circulation
Document management
Management archive
Drawings
Production archive
Maintenance archive
Discipline
Main Category
Category
Subcategory
Vendor data
books
TOS, SWO,
OC
Instructions
FC1100
Process Engineering Lifecycle Conference 2005
Request
14
Project archive
QESH archive
 Search, view
 Check-in / Check-out
 Version management
 Status management
 Redlining
Where are we today?
• Formalized manufacturing work processes are (being) implemented.
• ADW information architecture (Plant Breakdown Structure,
equipment and document classification, document status network,
etc) is designed.
• Functional requirements are specified.
• ADW prototype has proved suitability of SAP as software platform.
– SAP user-friendliness remains attention point
• Project to implement and roll-out first ADW version in preparation
phase.
Process Engineering Lifecycle Conference 2005
15