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© Copyright 2019 OSIsoft, LLC
Best Practices in Port AutomationMatt MillerJune 19, 2019
© Copyright 2019 OSIsoft, LLC
Introduction
Matt Millermmiller@osisoft.comTransportation Industry Principal
© Copyright 2019 OSIsoft, LLC
Webinar Topics
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Who is OSIsoft?
Future of Smart Ports
Best Practices in Automation
Learning From Other Ports
Q&A
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We BELIEVEPeople with DATACan TRANSFORMTHEIR WORLD
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© Copyright 2019 OSIsoft, LLC 8
Assets
MultipleSensors
Plant
MultipleAssets
Enterprise
MultiplePlants
Community
MultipleEnterprises
Sensors
Millions of Smart Devices
OSIsoft’s Strategy: From Sensors to Community
© Copyright 2019 OSIsoft, LLC© Copyright 2019 OSIsoft, LLC 9
Where Do Transportation Companies Find Value?OPERATIONAL
PERFORMANCERESOURCE &
FUEL MANAGEMENT
ENVIRONMENTALREPORTING & COMPLIANCE
ASSET HEALTH & RELIABILITY
• Fuel Optimization
• Water Conservation
• Energy Management
• Governmental Regulations
• Accident & Incident
• Emergency Response
• License to Operate Parameters
• Improved uptime
• Condition-based maintenance
• Asset Utilization & Depreciation
• Reduced Maintenance Costs
• Network capacity & throughput
• On-time arrivals• Capital
effectiveness• Operating
certifications• Automation
© Copyright 2019 OSIsoft, LLC© Copyright 2019 OSIsoft, LLC 10
Business Outcomes Enabled by the PI System
OPERATIONAL PERFORMANCE
& CAPACITY
RESOURCE & FUEL
MANAGEMENT
REGULATORY COMPLIANCE
ASSET MANAGEMENT &
RELIABILITY
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Select Transportation Customers
Rail Marine Trucks Ports
© Copyright 2019 OSIsoft, LLC
APPLICATIONS & ANALYTIC TOOLS
The PI System is a Real-time System of Recordfor Critical Operations
DATA SOURCESAutomation Systems
IoT Gateways
Control SystemsRemote Sensors & Assets
PEOPLEProcess EngineerProduction ManagerReporting AnalystOperations ManagementData ScientistMaintenance Engineer
Real-time Monitoring
Analytics, GIS, BIG Data
Specialized Applications
3rd Party Services
© Copyright 2019 OSIsoft, LLC 13
The PI System for Ports
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It’s Time to Find a New Way to Work
Operational Excellence
Operational Performance &
Capacity Increases
Resource & Fuel Optimization
Asset Management &
Reliability
Regulatory Compliance
“Catastrophic machines failures are much more expensive than planned downtimes.”
© Copyright 2019 OSIsoft, LLC 18© Copyright 2019 OSIsoft, LLC 18
Future of Smart Ports
© Copyright 2019 OSIsoft, LLC
The Future of Transportation is…Intelligent!
Connected
Sustainable
Collaborative
Automated
Electrified
All Driven by Real-time Data!
© Copyright 2019 OSIsoft, LLC20
Operational Excellence
Digital Transformation Unlocks New Opportunities
ProductInnovation
New Services
IncreaseRevenue
DigitalTransformation
ReduceCosts
© Copyright 2019 OSIsoft, LLC
Smart Port Challenges
• Increasing volumes – 400M ton/year globally*• $10B Automation investments are decreasing throughput!**• Environmental Compliance Pressure• Asset and Energy Intensive – long return on capital• Intermodal Price Pressure• Greater transparency to all stakeholders - Collaboration
*Source UNCTAD 2018 Review of Maine Transport** Source 2019 McKinsey The Future of Automated Ports Study
© Copyright 2019 OSIsoft, LLC 22
Smart PortsDigital Transformation
o Lean Approacho Perfect Order= Perfect Movemento Digital Maturity Model & Metricso Value Focused
© Copyright 2019 OSIsoft, LLC
Block Chain Operational Use Cases
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Asset lifecycle and history
Parts history
Maintenance/repair history
Events
Transfer of ownership
Supply chain
Ingredients
Manufacturers
Trackability / Traceability
Temperature controlled supply chains
Data
Provenance / Quality
Ownership
Monetization
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Blockchain Integration Partnerships
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+
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Realtime Data
Economy
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Realtime Data
Economy
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ManufacturerTestingSales
Logistic partnersCustomsFreight forwarders
Commissioning partnerCustomerTesting
Service departmentService partner
Supplier
DecommissioningRecycling partner
LegalNew owner
Testing
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© Copyright 2019 OSIsoft, LLC 29
The Future in the CloudOSIsoft Cloud Services
Connected Community
Data Science Enablement
Partner AppsPlatform
Remote Ops Monitoring
© Copyright 2019 OSIsoft, LLC 33© Copyright 2019 OSIsoft, LLC 33
Best Practice Steps
© Copyright 2019 OSIsoft, LLC
Best Practices in Automation
BASELINE YOUR OPERATIONS
BUILD A REAL-TIME OPERATIONAL SYSTEM
OF RECORD (SOR)
OPTIMIZE THE PROCESS FOR A "PERFECT
MOVEMENT"
PLAN FOR EXCEPTIONS NURTURE DATA ECOSYSTEMS
DATA DRIVEN
CULTURE
© Copyright 2019 OSIsoft, LLC 35
Baseline Operations
Collect the data first to know where you started Identify priorities and best investmentsRefine operating model (Digital Twin) Track phases of operation through the processAlign metrics and tactics with business strategy
© Copyright 2019 OSIsoft, LLC 36
Building a Real-time Operational SoR
Capture in original fidelity from as many sources as possibleData abstraction layer between business and operationsOne version of the operational “truth”Place to address data quality issuesSecure access to control and safety critical systemsManaged by Operations administered by IT
© Copyright 2019 OSIsoft, LLC 37
Optimize for the Perfect Movement
Analyze phases to determine where time is lostMeasure against plan in real-time Identify constraints Remove or reduce themRepeat…Automate
© Copyright 2019 OSIsoft, LLC
Plan for Exceptions
Meet the challenges of digitalizationConsistent asset integration across the enterprise Enable advanced analytics – prescriptive & predictiveIntegrate with other business systems of record
Consider Optimized Operational Envelopes Repeatable route segments using many assets Better understanding of activities and best practices Optimization tuning dependent on current goals (on-time, fuel, safety, wear)
Identify top risks to delivering expected outcomes and innovate!
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© Copyright 2019 OSIsoft, LLC 39
Nurture Collaborative Ecosystems
•On-time arrivals•Shorten lead-times•Resiliency•Reduce Waste/Cost•Lower risk•Emergency Management
© Copyright 2019 OSIsoft, LLC 40
Data Drive Cutlure
Empower all stakeholders with data for better decision makingMake it self-serve as much as possible Focus on who’s solution is bestNot who’s data is right
© Copyright 2019 OSIsoft, LLC 41© Copyright 2019 OSIsoft, LLC 41
Learning From Others
© Copyright 2019 OSIsoft, LLC“ ”
Port Information Management
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Unreliable access to asset data
Inefficiencies in fuel use and maintenance
Difficulty meeting compliance and capacity requirements
The PI System as a real-time, common data infrastructure across ports, vessels, cranes and terminals
Reduced fuel consumption, maintenance costs and downtime
Increased port throughput, revenue, and profit margins
CHALLENGES SOLUTION BENEFITS
The PI System integrates all our equipment data at the enterprise level. That helps us increase productivity and preserve the profitability
of our ports. Pradeep Gupta, Project Director, Adani
© Copyright 2019 OSIsoft, LLC
Operations before Implementation
Share planning with stakeholders
VTMS - Vessel at Anchorage
Berth planningDischarge sequence & Sub
sequence planning
Allocate Assets
Tugs boats –Anchorage to Berth
Actual Discharge Monitoring
Capture delay and stoppage reasons
Capture and share breakdown of assets
Forecasting of Vessel & Material
Re arrange the plan as per available assets
Monitoring deviations in plan
Monitoring movable assets & Safety
Reporting on asset performance
© Copyright 2019 OSIsoft, LLC
Operations after Project Implementation
Forecasting of Vessel & Material
Tugs boats –Anchorage to Berth
Capture delay and stoppage reasons
HMI
West Basin
FMS
WB WLS / TLS
VTMS
• Berth planning• Discharge Sequence & Sub
sequence Planning• Allocate Assets• Monitor Plan Vs Actual• Replan
Share planning with stakeholders
DVMS
Safety Assets
Weather
Advance QueuingVehicle Route PlanningSupply Chain Optimization
Planned
© Copyright 2019 OSIsoft, LLC“ ”
Equipment Logistic Strategies
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Port needed to support additional 10 Mt increase of throughput without any capital expenditure
The PI System isan information hub that managesall aspects of the supply chain, including KPI-based planning and predictive maintenance
Increased shipping capacity from 16 Mt to 26 Mt with no infrastructure investments
Increased capacity meant $120M of additional revenue in 2015
CHALLENGES SOLUTION BENEFITS
All of the information is available to everyone. Absolutely no limitation. Everybody from the shift operator all the way to the CEO is looking at
the same data and information is plastered everywhere.Michel Plourde, Director of Systems, ArcelorMittal
Mines Canada
© Copyright 2019 OSIsoft, LLC
Time Usage Model - A Practical Implementation
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Production
Production time
Production target
Startup Shutdown
Reduction
Operating = Process/Eqpt providing at required levelDelayed = Equipment not providing service level requiredStopped = Equipment/Process idleDown = Equipment brokenMaintenance = Scheduled Maintenance
© Copyright 2019 OSIsoft, LLC
One Information Source for Optimized Supply Chain Planning
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© Copyright 2019 OSIsoft, LLC“ ”
Improved Shipping Container Operations
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Inadequate tools and data for detailed process analysis
Disparate datasources that were not structured for quick insight
Integrated PI System with container-terminal systems to improve awareness
RMG Cycle Time decreased by more than 10%
Increased Maintenance Compliance: 100% on target
CHALLENGES SOLUTION BENEFITS
With the transition towards using PI to collect that data, not only do we save manpower in manually collecting readings, but the accuracy
and the repeatability of those readings is significantly improved.Mark Jensen, Assistant VP of Equipment and Facility Maintenance, TraPac
#OSIsoftUC #PIWorld ©2018 OSIsoft, LLC#OSIsoftUC #PIWorld ©2018 OSIsoft, LLC
Objective: Improve operational efficiency of RMG by improving travel times for its movements
Use Case: Improved Operational Efficiency –Optimizing RMG Travel Times
Automation Transfer Area
#OSIsoftUC #PIWorld ©2018 OSIsoft, LLC#OSIsoftUC #PIWorld ©2018 OSIsoft, LLC
Divide the RMG cycle into phases based on crane movement, job status, remote operator status, transfer area reservation status
Use Case: Improved Operational Efficiency –Optimizing RMG Travel Times
Move to Pick Location
Pick container
Move to Ground Location
Ground container
Horizontal
Lateral
Vertical
#OSIsoftUC #PIWorld ©2018 OSIsoft, LLC#OSIsoftUC #PIWorld ©2018 OSIsoft, LLC
Used Event Frames to quantify duration of each phase and create a baseline to help identify outliersResults• Quantified idle time crane movements
which provided necessary data to support programming changes to RMG PLC
• 10% improvement in cycle times
Use Case: Improved Operational Efficiency –Optimizing RMG Travel Times
#OSIsoftUC #PIWorld ©2018 OSIsoft, LLC#OSIsoftUC #PIWorld ©2018 OSIsoft, LLC
Objective: Leverage PI System to expedite troubleshooting
• Problem reported as significant reduction in RMG throughput
• Initial suspicions pointed to recent control-system update
• Problem was intermittent and visual inspection was inconclusive
Use Case: Expediting Issue Resolution
#OSIsoftUC #PIWorld ©2018 OSIsoft, LLC#OSIsoftUC #PIWorld ©2018 OSIsoft, LLC
Results
• Quick visual recognition of typical spreader profile versus bad
• Worked with mechanics to pinpoint issue – bent spreader flipper, distortion undetectable
• Without PI data, would be guessing at issue
• “Unless we went out there with a straight edge, we may still be searching for the cause!”
Use Case: Expediting Issue Resolution
BAD
GOOD
Moving to Pick Location
Smooth change in hoist direction
Hoist is “bouncing” to pick container
Pick Attempt
#OSIsoftUC #PIWorld ©2018 OSIsoft, LLC#OSIsoftUC #PIWorld ©2018 OSIsoft, LLC
Objective: Leverage PI System to digitalize maintenance workflow and improve maintenance interval compliance
• PI AF configured to send email to third-party CMMS daily using PI Analysis, PI Event Frames and PI Notifications
Use Case: Improving Maintenance
#OSIsoftUC #PIWorld ©2018 OSIsoft, LLC#OSIsoftUC #PIWorld ©2018 OSIsoft, LLC
Use Case: Improving MaintenanceStraddle Carrier• Automated container transport
vehicle• Travels freely between equipment• Operates in fenced-off automated
area• Breakdowns may not be addressed
until work stoppage
#OSIsoftUC #PIWorld ©2018 OSIsoft, LLC#OSIsoftUC #PIWorld ©2018 OSIsoft, LLC
Results: Data provided by PI System helps drive the PM maintenance regime within our CMMS, particularly for meter driven PM, resulting in a significant upward trend in PM creation
Use Case: Improving Maintenance
#OSIsoftUC #PIWorld ©2018 OSIsoft, LLC#OSIsoftUC #PIWorld ©2018 OSIsoft, LLC
Results: Timely and accurate data has resulted in a significant shift in compliance to PM schedules
• Autostrad PM is typically based on a 200 hrs inspection and a hierarchical 1,000 hrs service interval.
• Actual intervals against this target have been tracked for gauging PM Schedule Compliance.
• PM Scheduling compliance: -0/+10%: on target. -0/+5%: considered hitting the bullseye.
Use Case: Improving Maintenance
#OSIsoftUC #PIWorld ©2018 OSIsoft, LLC
Interval Count of Interval % <950 76 48%950-999 11 7%1000-1049 17 11%1050-1100 12 8%>1100 42 27% Total Count 158
PM Schedule Compliance – 1,000hrs servicingPrevious method – prior to Jun 2017
PM Schedule Compliance 1,000hrs servicingNew method –Since Jan 2018
11% bullseye19% on target
More data is desirable before declaring an outstanding success but the indicative trend so far is very favorable.
The new method supported by PI sees good accuracy and repeatability for the 200hrs inspections interval. The previous method never captured 200hrs inspection data for comparison.
Use Case: Improving Maintenance
80% bullseye100% on target
Interval Count of Interval % 1000-1049 28 80%1050-1099 7 20%Total Count 35
© Copyright 2019 OSIsoft, LLC
Best Practices in Port Automation• Key to Smart Ports is driving value added digital
transformations
• Real-time Operational System of Record supports scale & time to value
• Follow cross industry best practices and steps
• Collaborate through data communities
© Copyright 2019 OSIsoft, LLC
• Go to our website
• www.osisoft.com\transportation
• Email me mmiller@osisoft.com
Want more information?
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THANK YOU
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