digitale fabriek - i2 - dsquare

18
Production excellence through real-time decision support D square: http://www.dsquare.be Friday 30 March 2012

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Inleiding op deel 6 van de seminariereeks Digitale fabriek. Digitale fabriek als een van de transformaties van Factories of the Future.

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Page 1: Digitale fabriek - I2 - Dsquare

Production excellence through real-time decision support

D square: http://www.dsquare.be

Friday 30 March 2012

Page 2: Digitale fabriek - I2 - Dsquare

Operational Excellence

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Friday 30 March 2012

Page 3: Digitale fabriek - I2 - Dsquare

From data sinks to information sources, from iT to IT

D square: http://www.dsquare.be

Friday 30 March 2012

Page 4: Digitale fabriek - I2 - Dsquare

From data sinks to information sources, from iT to IT

D square: http://www.dsquare.be

Friday 30 March 2012

Page 5: Digitale fabriek - I2 - Dsquare

Plant conditions

Shift logbook

Shift handover

Production meeting

ENTERPRISE RESOURCE PLANNING

From data sinks to information sources, from iT to IT

D square: http://www.dsquare.be

Friday 30 March 2012

Page 6: Digitale fabriek - I2 - Dsquare

Plant conditions

Shift logbook

Shift handover

Production meeting

ENTERPRISE RESOURCE PLANNING

SCADA - DCS

PROCESS CONTROL

PIMS LIMS ALARM EVENTS

PRODUCTION QUALITY EFFICIENCY MAINTENACE

From data sinks to information sources, from iT to IT

D square: http://www.dsquare.be

Friday 30 March 2012

Page 7: Digitale fabriek - I2 - Dsquare

From data sinks to information sources, from iT to ITFriday 30 March 2012

Page 8: Digitale fabriek - I2 - Dsquare

Real-time decision support

http://www.dsquare.be

Process watchdog

Process logbook

Process coach

Friday 30 March 2012

Page 9: Digitale fabriek - I2 - Dsquare

D square: http://www.dsquare.be

Friday 30 March 2012

Page 10: Digitale fabriek - I2 - Dsquare

Data mining: science, art or magic?

D square: http://www.dsquare.be

Friday 30 March 2012

Page 11: Digitale fabriek - I2 - Dsquare

Data mining flavors

Data mining: science, art or magic?

• Soft sensors

• Anomaly detection

• Adaptive control

• Defect classification / analysis / prediction

• Root-cause analysis

• Operator action advise

• KPI prediction

• Planning and scheduling

• ...

Friday 30 March 2012

Page 12: Digitale fabriek - I2 - Dsquare

Data mining: science, art or magic?

• What is the question?

• Is the answer in the data?

• Involvement & expectations?

• Where is the expert?

• Is there sufficient context?

Data mining success criteria

Friday 30 March 2012

Page 13: Digitale fabriek - I2 - Dsquare

Case study: Operator action advise

D square: http://www.dsquare.be

Friday 30 March 2012

Page 14: Digitale fabriek - I2 - Dsquare

Waste incinerationFriday 30 March 2012

Page 15: Digitale fabriek - I2 - Dsquare

Motivation

• Significant variation on the decisions taken by panel operators

• Variations in operator behavior are believed to have significant effects on important process KPIs such as steam flow

• Expertise of senior operators may not be fully exploited to assist more junior operators when difficult decisions need to be made

• Data of operator actions and their effects is readily available in todays data historians.

• There is a gap between the operational and managerial level that makes it difficult to implement performance optimal plant operation. It is hard for managers to relate operator behavior to process performance.

• A feasibility study has indicated that potential ROI of a decision support system is signficant

Friday 30 March 2012

Page 16: Digitale fabriek - I2 - Dsquare

Differential operator team analysisFriday 30 March 2012

Page 17: Digitale fabriek - I2 - Dsquare

Results

• Determined influence factors for steam loss

• Differential operator analysis

! Across teams

! Problems due to inefficient shift handover

• Implementation of an operator advisory system (process GPS)

! Action advise

! Action insight

Friday 30 March 2012

Page 18: Digitale fabriek - I2 - Dsquare

Production excellence through real-time decision support

http://www.dsquare.be

D square: http://www.dsquare.be

Friday 30 March 2012