Empowering Business in Real Time. © Copyright 2009, OSIsoft Inc. All rights Reserved. PI Baking...

Empowering Business in Real Time. © Copyright 2009, OSIsoft Inc.  All rights Reserved.  

“PI Baking” Contest

Regional Seminar SeriesPhiladelphia

Pete LongPI AdministratorGlatfelter, Spring Grove, PA

October 13, 2009

2 Empowering Business in Real Time. © Copyright 2009, OSIsoft Inc.  All rights Reserved.  

1863 - First Paper Machine

3 Empowering Business in Real Time. © Copyright 2009, OSIsoft Inc.  All rights Reserved.  

Today’s Paper Machines

4 Empowering Business in Real Time. © Copyright 2009, OSIsoft Inc.  All rights Reserved.  

Spring Grove Architecture…

4

Interface node

Analytical tools

- Performance Eq.- Control Monitor- email Notifications

Spring Grove…

- ProcessBook - Datalink - Control Monitor

Data Source(DCS, PLC, etc)

Other systems

- ERP - Maintenance - LIMS - CEMS

PI Servers

…Client stations

- ProfileView - SQC - DevNet Utilities

Interface node

Data Source(DCS, PLC, etc)

5 Empowering Business in Real Time. © Copyright 2009, OSIsoft Inc.  All rights Reserved.  

Glatfelter: Everyone Benefits when everyone is involved.

•“Simply put, the more people that contribute to our PI system, the better the intelligence we get from it. The different perspectives allow us to collectively mine more information from the data.” 

•Steve Groetz, Process Automation Manager.

Customer Business Challenge

Solution Customer Results / Benefits

• Finite engineering workforce exercising a broad range of disciplines.

• Limited capitol resources: “making do with what we have”

• Wealth of mill wide process data in PI not being effectively interrogated.

• Create an initiative to generate individual motivation beyond the engineering department to the entire workforce exploiting PI data with goals of improving visibility, reducing time, increasing quality, and reducing costs.

• ProcessBook & DataLink projects were received from 6sigma black belts, lab techs, and process engineers.

• Projects were essential to prove a business case, provide real-time process information, and compare current runs to QC standards.

• On project continues to verify and maintain quarterly savings of over $100k.

Pulp and Paper

6 Empowering Business in Real Time. © Copyright 2009, OSIsoft Inc.  All rights Reserved.  

Looking for a Super Hero!

6

7 Empowering Business in Real Time. © Copyright 2009, OSIsoft Inc.  All rights Reserved.  

…easy as PI -or- PI is so easy a…

7

8 Empowering Business in Real Time. © Copyright 2009, OSIsoft Inc.  All rights Reserved.  

OSIsoft Collaboration

8

9 Empowering Business in Real Time. © Copyright 2009, OSIsoft Inc.  All rights Reserved.  

Contest example… “Value Now”

9

Problem: Inability to trend Control Monitor stats in ProcessBook

Solution: Extract data from CM database into Excel and filter, sort, trend and report in Excel

Result: Improved visibility of loop performance data

10 Empowering Business in Real Time. © Copyright 2009, OSIsoft Inc.  All rights Reserved.  

Contest example… “Value Now”

10

11 Empowering Business in Real Time. © Copyright 2009, OSIsoft Inc.  All rights Reserved.  

Contest example… “Value Now”

11

Real Time PI Data

Real Time PI Data

Real Time MES DataReal Time MES Data

Averaged PI Data

Averaged PI Data

Problem: QC and Mfg wanted to compare real time scanner data against lab test results as soon as possible

Solution: Use ODBC data sets in ProcessBook to access MES system and display lab data and control limits against real time measurements

Result: Ability to make control decisions and correct problems in real time. Minimize waste and rework

12 Empowering Business in Real Time. © Copyright 2009, OSIsoft Inc.  All rights Reserved.  

Contest example… “Value Now”

12

Problem: Many grade variations with variable property setpoints hard to document and display

Solution: Collect actual properties per run and display so operator can easily compare current to previous runs

Result: Visualization of data from prior runs enables operators to quickly and easily see if they are on track for the specific grade and make adjustments in real time.

13 Empowering Business in Real Time. © Copyright 2009, OSIsoft Inc.  All rights Reserved.  

Contest example… “Value Now”

13

14 Empowering Business in Real Time. © Copyright 2009, OSIsoft Inc.  All rights Reserved.  

Contest example… “Value Now”

14

15 Empowering Business in Real Time. © Copyright 2009, OSIsoft Inc.  All rights Reserved.  

Contest example… “Value Now”

15

16 Empowering Business in Real Time. © Copyright 2009, OSIsoft Inc.  All rights Reserved.  

And the Winner is…

16

17 Empowering Business in Real Time. © Copyright 2009, OSIsoft Inc.  All rights Reserved.  

Future Drives… “Value over Time”

17

18 Empowering Business in Real Time. © Copyright 2009, OSIsoft Inc.  All rights Reserved.  

Future Drives… “Value over Time”

18

19 Empowering Business in Real Time. © Copyright 2009, OSIsoft Inc.  All rights Reserved.  

Wrap-up… “Value Now, Value over Time”

19

Project

C.M. Trending

3D Profiles

Lab Compare

Run Properties

P.M. Overview

Cost vs. Quality

Adv. Calc. Tutorial

B.R. Efficiency

SaveMoney

SaveTime

ImproveVisibility

IncreaseProduction

ReduceDowntime

20 Empowering Business in Real Time. © Copyright 2009, OSIsoft Inc.  All rights Reserved.  

Glatfelter: Everyone Benefits when everyone is involved.

•“Simply put, the more people that contribute to our PI system, the better the intelligence we get from it. The different perspectives allow us to collectively mine more information from the data.” 

•Steve Groetz, Process Automation Manager.

Customer Business Challenge

Solution Customer Results / Benefits

• Finite engineering workforce exercising a broad range of disciplines.

• Limited capitol resources: “making do with what we have”

• Wealth of mill wide process data in PI not being effectively interrogated.

• Create an initiative to generate individual motivation beyond the engineering department to the entire workforce exploiting PI data with goals of improving visibility, reducing time, increasing quality, and reducing costs.

• ProcessBook & DataLink projects were received from 6sigma black belts, lab techs, and process engineers.

• Projects were essential to prove a business case, provide real-time process information, and compare current runs to QC standards.

• On project continues to verify and maintain quarterly savings of over $100k.

Pulp and Paper

Thank youThank you

© Copyright 2009 OSIsoft, Inc.

 777 Davis St., Suite 250 San Leandro, CA 94577