enabling enterprise operational intelligence in the

© Copyright 2015 OSIsoft, LLC

Presented by

Enabling Enterprise Operational Intelligence in the

Process Industries:

Improvements,

Innovation

and Reinvention

Dr. Osvaldo A. Bascur,

IP and OSIPress Initiative


Abstract: Large industrial complexes have more data than a small city and much it is in “real-time”, changing rapidly as internal and external conditions evolve. As corporations buy and sell assets and reengineer their staff, the structure and tools that were used to understand these data are lost. This results in significant deterioration in the ability to maintain a “smart” operation. By embracing a real-time infrastructure with a data centric approach mining companies are enabling their people to optimize the availability of their assets and reducing operating costs. The integration of chain supply for asset and energy optimization are one off the most critical factor due to the large changes in the raw materials. This presentation summarizes how early adopters are empowering their local and strategic support teams to get insight from the overall process effectiveness index based on key variables such as losses due to (mobile or static) equipment availability, energy savings, and production optimization. Three commonalities become evident: People empowerment aligned to Enterprise Mission, A continuous Improvement and Innovation program at the local and enterprise, and A data Infrastructure to facilitate local operational intelligence and enterprise intelligence. In summary, these organizations are embracing a smart data infrastructure to move ahead to become leaders in their field.

2


Defining our Journey to Operational Excellence

Conclusion and Call to Action

3

Agenda

Are you really using your information?

Current Industry Challenges and the Evolving Operations

Examples of Success


Rethinking our approach to innovation

Collaboration

Creating sustainable value

New

approaches

Knowledge

transfer

Local partnerships

4


Innovation is the key to solving these challenges

Mining needs to leap forward 20 years in the next five

5


Coordination and Integration

Engineering

Project Schedule

Task 1 Project Area 2

Task 1 Task 2

Project Area 1

Task 2

Resources / Cost Control

Simulation Design/ Cost

Engineering Standards

Distribution / Orders / Scheduling

Inventories

Data Reconciliation

LP Model

Plant Wide Optimization

Inventory Plans

Process Targets

S

U

P

P

L

I

E

R

S

C

U

S

T

O

M

E

R

S

Performances

Rules

• Government

• Stockholders

• Human Resources

• Financial Markets

• Crude Supply

Outside

Influences Jan

March

May July

Strategic

Business

Plan

Sep

Nov.

Reporting

Execution

Planning

Communication

Assessment

Measuremen

t

Operations Maintenance

Feed

Stock

Inv.

Just in Time

Training

Process Safety

Management

Performance

Monitoring

P1

P2

Specials

Prod

Tanks

Approvals

Proposals

Yields

Costs

Markets Needs Specs Training

6


Infrastructure Data Engineering Analysis for the Enterprise

7

Enterprise

Division

Plant

Unit IDEA


Coordination and Collaboration

RM TRANSF O C1

R

C3

Waste

MANUF PRODUCT C4

T

Tons Processed

Heats, Consumables

Power & Water Usage

Asset Information, Process Data

Tons

Grade, Assays,

Samples

Losses

C2

Presentation Layer

Support Plant

Management

Operations

Maintenance Engineering

Services Customers

Visualization Tools

Tons Shipped

Tons Trucked

Operations

Delays

Power & Water

Usage

Consumables

Receivable

& Storage

Ship

Loading

Port

Operations

and Delays

Transactions

8


Enterprise Dynamic Performance and Notification

PLANT INPUTS PRODUCTS

Data

Validation

Costs

Reduction

Event

Detection

Asset

Conditions

Metrics, KPI

Inventories

Controls Data

Capture

Plant

Optimization Improvements

Class.

Analysis

Model

Estimation

Process

Coordination

Panel

Station

Planning

Management

Operations

Maintenance

Alarm

Summaries

RT

History

PI-AF

SQL

Server

1988, ISA

Bascur

9


Bimodal Continuous Improvement and Innovation

10

• One

Center

Metrics: Production, Quality, Costs, Equipment Availability, Environmental and Safety alerts

with fast resolution and improved decision making.

Continuous Improvement and Innovation

MONITOR

In Control?

Identify Root

Causes

Yes Yes

No No

Real Time

Evaluation

of Metrics =>

Local Operations/Maintenance

Left Brain

MONITOR

In Control?

Identify Root

Causes

Yes

No

IMPROVE

Establish

Alternatives

Satisfied?

Operations/Maintenance

Strategic Competence Centers

Maintenance/Engineering/Management

Right Brain

Mines, Mills,

Smelters,

Refineries

$ $

Technology

Change

Behavior

Process

Plants


Production Energy Fuel Water Limestone

11




12

Agenda



Examples of Success

© Copyright 2015 OSIsoft, LLC 13

Enterprise

Agreement

First

PI System

Installed

Expanding

PI System

Installs

Worldwide

PIMS Project

PI Infrastructure

as Enterprise

Platform

Cement

Production

Management

PI System Infrastructure in CEMEX

1995 1995-2004 2005 - 2006

2007 - 2008

2009 - 2010

2011 - 2013

EA Agreement – Access to Industry

Principals, Center of Excellence,

Software, etc.


Cemex Production Model

14

Equipment

Production Capacity

Equipment Operation

Schedule Hours Inventory

Levels

Maintenance Production Kwh Low Heat Value

DVM

Sys. Administrator Plant Configuration Daily Validation SAP Interfaces Reports


Cement Production Model

OSIsoft EA PI System Infrastructure

ERP Systems BI Systems

Quality

Management

Production Data

Validation

Energy

Management

Emissions

Management Condition Base

Maintenance

CP

M


16


Sustainable Value Added to the Enterprise

17

Center for Monitoring and Diagnosis

On Line Analytics

Operational

Excellence

Continuous Improvement

and Value Creation

17


Drastic Energy Reductions

18


Future: Moving into Interconnected

Systems

19

Mining and Metallurgical

Enterprise

Mobile

Equipment

Manufacturer

Equipment

Manufacturer

Chemical

Manufacturer

Power

Generation

Government

External

Engineering

Support

Cloud

Universities

Chris

Mining

Video Outotec

Finland




20

Agenda



Examples of Success


Towards Operational Intelligence

Synchronize Business Processes With Operational Processes

Stream Line

Integration

Transformation

21


7 Key areas for Operational Improvements

• 1. - Production Monitoring

• 2. - Quality Monitoring

• 3. - Asset Monitoring

• 4. - Energy-Water-Reagents Monitoring

• 5. - Environmental Monitoring

• 6. - Safety Monitoring

• 7. - Systems Monitoring

22


A Five Tier Framework for Business Optimization

24

Presentation Layer

Support Plant

Management Operations

Maintenance

Engineering

Services Customers

Visualization Tools

Knowledge Coordinator

Repository Manager

Cloud Virtual Server Data Services DataBase

Application Layer

Data Servers

Mission, Strategy and Goals

Business Process

Business Improvement Process

Plant Process Flow Diagram


Standardizing for common understanding

the Process Industry Unit Template

25

• Raw Materials

• Select Major Process Areas

• Input - Output Production Streams

Consumption (Energy, Water, Materials)

Inventories

• Define Process and Equipment Events

– Do not use quality measure at the object level

Process Industry

Unit

Template

Input Output

Consumption Waste

Availability

Safety

Scheduled Targets, Process Requirements


Operational Intelligence Basics

26

Data Context + Events Information Insight Actionable Information

Data Classification

Event Generation

Data Aggregation

Notifications

Operational

Intelligence

Data

Discovery

Notifications

Data Classification

Event Generation

Data Aggregat

ion

Notifications

Enterprise

Intelligence

Data Analysis

Notifications

People Infrastructure Engineering Analysis


Continuous Improvement and Innovation

MONITOR IMPROVE

In Control?

Identify Root

Causes

Establish

Alternative

Yes Yes

No No

Satisfied?

Metrics

Requests Results

Production

Quality

Equipment

Energy

Water

Costs

Environmental

Safety

Communities

Yields

Quality Products

Equipment Availability

Energy/ton

Specific/ton

Cost/ton

Losses

Waste

Emmissions

Incidents

Targets Dollars

Data and Events Empowerment

Materials Process O C1

R

C3

Waste

Products Shipping C4 T

Reject C2

1.- Strategic

2.- Support

3.- Real Time Enabling Enterprise Operational Intelligence

27


Towards Integrated Business and Operational Intelligence

• Integrated Planning,

Continuous

Improvement and

Innovation Process

28


Excellence in Sustainability Programs!

Operational

Intelligence

CONTINUOUS Improvement and

Innovation

Enterprise Intelligence

Business / People

Achieving Improvements on water and

energy usage

results in direct financial benefit

Positioned as development partner of

choice with the Local

Government, Communities and Value

from Sustainability programs

Avoid surprise events, reduce the costs

associated with stoppages.

29




30

Agenda



Examples of Success


Things to think about

• Embrace the use of data and analytics to anticipate disruption and analyze responsive scenarios.

• Consider how to provide infrastructure and investment for incubating and scaling growth, new ideas and innovation.

• Business processes through the entire value chain of industrial process shift to digital-driven and human enabled model.

31


Infrastructure Data Engineering Analysis for the Enterprise

32

Enterprise

Division

Plant

Unit IDEA


Infrastructure Data Engineering Analysis

Osvaldo Bascur

[email protected]

IP and OSIPress Initiative

OSIsoft, LLC

mailto:[email protected]


Questions

34

Please wait for the

microphone before asking

your questions

State your

name & company


Summary: Operational Intelligence Foundation

People

Bimodal Continuous

Improvement and

Innovation

Infrastructure

Operational

Intelligence

Business

Intelligence

Enterprise

Intelligence

35


Interfaces

Data Events Capture

and Storage

Data Classification

Models, Real Time

Predictive Analytics,

Views, Aggregation at

Detail

Business Views

Data Analysis,

Cubes, Modelling

Presentation and

Consumption

Monitor Strategy

Measure Action

Enterprise

Plant

Area

Unit

Expert User

User

Collaboration User

Real Time Data Capture

Real Time Event Capture

Real Time Data Classification

Real Time Data Aggregation

Real Time Data Notification

Data Classification

Event Generation

Data Aggregation

Notifications

Improve Strategy

Measure Action

Root

Cause

Improvement

and

Innovation

36

enabling enterprise operational intelligence in the

Documents