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Reaching across boundaries, collaboration, Web Parts, and Notifications. Jim Cummins Manager: Process Information. SMI: Sharing Information World Wide. - PowerPoint PPT Presentation
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1 Empowering Business in Real Time. © Copyright 2009, OSIsoft Inc. All rights Reserved.
Reaching across boundaries, collaboration,
Web Parts, and Notifications
Jim Cummins
Manager: Process Information
2 Empowering Business in Real Time. © Copyright 2009, OSIsoft Inc. All rights Reserved.
“Specialty Minerals has a very dispersed work force with small facilities located around the world. Consolidating and surfacing production information is essential for daily management. Web Parts is a tool that integrates well with our web based communications. “
Customer Business Challenge
Solution Customer Results / Benefits
SMI: Sharing Information World Wide
• Collect accurate process information from small facilities located globally.
• Provide a single source for viewing many locations and processes to employees in non centralized locations.
• Communicate requirements to suppliers for automated deliveries.
• Implemented a single PI server with interfaces to manufacturing facilities world wide.
• Implemented MS SharePoint with PI web parts to expose process information.
• Implemented notifications tied to inventory to Email suppliers.
• Dashboards and process analysis are driving continuous improvement ; lowering product costs improving performance.
• Integration of information from multiple data sources.
• Timely, reliable, communication for material suppliers.
3 Empowering Business in Real Time. © Copyright 2009, OSIsoft Inc. All rights Reserved.
Specialty Minerals
Synthetic Calcium Carbonate
Facilities: 53 located globally
Employees: 3 to 15 per location
Symbiotic relationship with paper mill
Paper Machine
Paper MillLime
Source
Chemical
Sources
Local
Labor
MTI Proprietary Technology
Gas
H20
Waste
Power
PCC
Plant
PCC Slurry
4 Empowering Business in Real Time. © Copyright 2009, OSIsoft Inc. All rights Reserved.
Facility Design
• Facilities are highly automated using Siemens PCS7 DCS systems.
• Plants are or can be operated by a single individual or in many cases unmanned for periods of time.
• Plants will run continuously 24X7 as needed to meet mill demand.
• Product is delivered to host mill by pipe line.
• Off site customers are supported with truck deliveries.
5 Empowering Business in Real Time. © Copyright 2009, OSIsoft Inc. All rights Reserved.
Our History with OSIsoft
• PI server was installed in Easton PA. data center in 2007. Data interfaces were installed at 8 facilities replacing local data Historians.
• Additional facilities were added in 2007 and 2008 including locations in Europe, Africa, South America, and Asia. PI ACE was added to populate batch tables in SQL Server.
• MS SharePoint Server was deployed with PI Web parts to expose process data on the secure company network.
• PI to PI interface has been used to link directly with the customer.
• PI Notifications has been used to communicate inventory levels to raw material suppliers.
6 Empowering Business in Real Time. © Copyright 2009, OSIsoft Inc. All rights Reserved.
Interface and data collections
• Each of the facilities use a PI OPC interface installed on the Siemens PCS7 process control system operator interface computer.
• Process data is continuously streamed to the central server. Data is buffered at the plant in the event of a connectivity loss.
• PI Batch and PI ACE are used to create batch records in SQL Server.
7 Empowering Business in Real Time. © Copyright 2009, OSIsoft Inc. All rights Reserved.
Challenge
Business processes needed to be stream lined.
Data quality, Timeliness, Labor, results distribution.
8 Empowering Business in Real Time. © Copyright 2009, OSIsoft Inc. All rights Reserved.
Challenge: Time to collect and Quality
of dataCollecting information from each plant required many forms and manual
data collection
10 Empowering Business in Real Time. © Copyright 2009, OSIsoft Inc. All rights Reserved.
ChallengeData consolidation and Analysis
11 Empowering Business in Real Time. © Copyright 2009, OSIsoft Inc. All rights Reserved.
Challengedata storage, access, and
reporting
12 Empowering Business in Real Time. © Copyright 2009, OSIsoft Inc. All rights Reserved.
Challenge
Business processes needed to be stream lined.
Data quality, Timeliness, Labor, results distribution.
13 Empowering Business in Real Time. © Copyright 2009, OSIsoft Inc. All rights Reserved.
Solution
Business processes needed to be stream lined.
Data quality, Timeliness, Labor, and Reporting .
14 Empowering Business in Real Time. © Copyright 2009, OSIsoft Inc. All rights Reserved.
The Solution: Data Collection
• Install PI Server in Easton PA with interface to all facilities.
• Collect process data for each plant using PI OPC Interface
• Implement PIBaGen (PI Batch Generator)
• Utilize PI Process Book and Data Link
One Source for process informationOne version of the truth
15 Empowering Business in Real Time. © Copyright 2009, OSIsoft Inc. All rights Reserved.
The Solution: Consolidation
• Collect process data for each plant on one server.
• Implement ACE to create Batch Records in SQL Server.
• Plant information Roll up capabilities
One Source for process information.One version of the truth.
16 Empowering Business in Real Time. © Copyright 2009, OSIsoft Inc. All rights Reserved.
The Solution: Reporting
• Expose summary information using MS SharePoint
• PI Web Parts for quick summary of process information
• PI Notifications for supplier communication
One Source for process information.One version of the truth.
17 Empowering Business in Real Time. © Copyright 2009, OSIsoft Inc. All rights Reserved.
Solution
Business processes needed to be stream lined.
Data quality, Timeliness, Labor, and Reporting .
Connection to each facility
SIMATIC S7
Local Programming
Production network
HMI
MTI Firewall
Plant Firewall
PI Historian and web server
End user tools
PI WebParts
OPC Interface
Typical Plant Configuration
Office network
CollaborationCollaborationContenConten
t t ManagManagementement
Electronic
Forms
Intranet / Intranet / ExtranetExtranet
Search
Business Business IntelligenceIntelligence
MOSSMOSS
“Extensible Server design”Initial Setup
Growth
Company Wide Implementation
Controlling costExpansion capability over time without
losing past investment
20 Empowering Business in Real Time. © Copyright 2009, OSIsoft Inc. All rights Reserved.
Significant steps to implementation1. Initial deployment of PI
a. Install and manage PI server.
b. Install and manage interface on each
control system.
c. Use PI client tools including data link and
process book to involve end users. Show
immediate benefits in data acquisition and
analysis.
d. Listen for suggestions to improve analysis.
21 Empowering Business in Real Time. © Copyright 2009, OSIsoft Inc. All rights Reserved.
Significant steps to implementation2. Add more value over time with
each new application.
a. Install and manage PI Batch.
b. Install and manage PI ACE.
c. Install SQL Server.
d. Configure your batch triggers and create
batch records from continuous data.
e. Involve end users. Show immediate
benefits in data acquisition and analysis.
22 Empowering Business in Real Time. © Copyright 2009, OSIsoft Inc. All rights Reserved.
Significant steps to implementation3. Add value with each new
application
a. Install and manage MS SharePoint .
b. Install PI Web Parts and Baseline.
c. Create and publish batch summaries using tree
view, table views, Time, and batch view.
d. Create pages to show plant KPIs, production,
and other related information.
e. Involve end users.
23 Empowering Business in Real Time. © Copyright 2009, OSIsoft Inc. All rights Reserved.
Significant steps to Benefits
4. Listen to end users and get them involved.
a. Develop actionable web pages from web parts
to support internal company operations,
management, and reporting requirements.
b. Improve your relationship with customers by
implementing a PI to PI interface to their PI
system.
c. Communicate to suppliers using PI
Notifications.
24 Empowering Business in Real Time. © Copyright 2009, OSIsoft Inc. All rights Reserved.
Benefits
One source of the truth + Improved accuracy + Faster recognition of opportunities + Informed decisions = Lower costs
25 Empowering Business in Real Time. © Copyright 2009, OSIsoft Inc. All rights Reserved.
Benefits
• Reduced time to collect and collate data
• Removes one roadblock to unmanned operation
• Accurate and verifiable data
• Removes one roadblock to unmanned operation
• One source for process data
• Every one works off the same data source
• Reduction in time spent validating information
• One version of the truth
26 Empowering Business in Real Time. © Copyright 2009, OSIsoft Inc. All rights Reserved.
Benefits
• Process metrics including OEE calculations
• Data to measure KPIs
• Real time access to information from anywhere
• Export from web site to Excel for unique analysis using third party modeling software.
Supporting the Continuous Improvement Process
Collect Data
Identify Opportunity
Analysis
Solution
Feedback
With WebParts
CollaborationCollaborationContent Content ManageManage
mentment
Electronic Forms
Intranet / Intranet / ExtranetExtranet
Search
Business Business IntelligenceIntelligence
MOSSMOSS
PI Web Parts
28 Empowering Business in Real Time. © Copyright 2009, OSIsoft Inc. All rights Reserved.
Current Challenges
• Migration from SharePoint 2003 to SharePoint 2007
• Building content at the rate it is requested.
29 Empowering Business in Real Time. © Copyright 2009, OSIsoft Inc. All rights Reserved.
“Specialty Minerals has a very dispersed work force with small facilities located around the world. Consolidating and surfacing production information is essential for daily management. Web Parts is a tool that integrates well with our web based communications. “
Customer Business Challenge
Solution Customer Results / Benefits
SMI: Sharing Information World Wide
• Collect accurate process information from small facilities located globally.
• Provide a single source for viewing many locations and processes to employees in non centralized locations.
• Communicate requirements to suppliers for automated deliveries.
• Implemented a single PI server with interfaces to manufacturing facilities world wide.
• Implemented MS SharePoint with PI web parts to expose process information.
• Implemented notifications tied to inventory to Email suppliers.
• Dashboards and process analysis are driving continuous improvement ; lowering product costs improving performance.
• Integration of information from multiple data sources.
• Timely, reliable, communication for material suppliers.
30 Empowering Business in Real Time. © Copyright 2009, OSIsoft Inc. All rights Reserved.
Jim CumminsManager: Process InformationSpecialty Minerals Inc.Jim.Cummins@mineralstech.com
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