Driving Operational Performance by building Manufacturing Capability one step at a time…

Driving Operational Performanceby building Manufacturing Capability one step at a time…..

Phillip Terlesk

2Copyright © 2013 Rockwell Automation, Inc. All rights reserved.

Agenda

2

Opportunity

Present State For Many

Manufactures

Collaborate to leverage the Opportunity

Customer Use Case

Questions


Global population will exceed 7 billion

More than 70 million will enter the middle

class

Middle class adding $8 US trillion to consumer spend

BEST IN CLASS DEMANDS

Operating Excellence

Compliance

Dynamic Value Creation

$8


Growth Matrix – Wine is a STAR!


Growth Matrix – Infant Formula


Infant Formula / Nutritional Powders

6


Value Add will drive growth


Adding Value will build export $$


9 9

v

MANUFACTURINGOPERATIONSCAPABILITY

Product Innovation

Reduce Waste

Process Innovation

Raw Materials

Time

People

Chemical / Energy

Capability To Bring Profitable Products to Market Faster

Dynamic Value CreationSucceeding in a Changing Market Place

Market Data


Agenda

10

Opportunity


Manufactures


Customer Use Case

Questions


Questions We Face On a Daily Basis ?

Did we stay within range on all Quality parameters during

Fermentation

Did we meet the CIP targets during the cleaning cycle?

• Temp• Time

Have I completed &

signed off all the preflight checks before starting the new batch?

Have we set up our coders correctly

Are our labels and packaging material correct & serialised


Business, IT & Automation Investment may not be 100% Aligned

Control Systems

HMIs

ManufacturingOperationsManagement

Alarms/Events

Other Database s

Computerized Maintenance Management Systems

Performance Management

Quality Systems

ProductionHistorians

Laboratory Information Management Systems


Process, Packaging &

Safety Automation

Building Capability one investment ata time

Manufacturing Operations

Management

ERP

Manufacturing Intelligence Process OptimisationChange & Asset Management

StandardOperating &Procedures


For the Operators Monitoring process to keep production

running Identifying relationships to optimize the

process

Operator

For the Production Manager Schedule, track production activity Way production is running, ways to improve

Production

For the Engineering / Maintenance Manager Keeping plant running Predicative maintenance, asset

optimization

Engineering

For the Quality Manager How product was made, ensure

compliance Ways to improve product and yield

Quality

For the Executive Costs, schedules, production output Financial indicators, sustainability

Plant Mgmt.

Deliver the correct Information

14


Agenda

15

Opportunity


Manufactures


Customer Use Case

Questions


Collaborate to Prioritise Objectives & Align Capability

ExecutionInnovationCompliance

Performance FocusLine & Site Specific

Reports&

KPI’s

Business DriversBusiness Drivers Align CapabilityAlign Capability

PeoplePeople

ProcessesProcesses

MaterialMaterial

EquipmentEquipment

Quality / Yield Quality / Yield

ThroughputThroughput

EnergyEnergy

xxx $$$ xxxxxx $$$ xxx

High levelBusinessObjectives


Agenda

17

Opportunity


Manufactures


Customer Use Case

Questions

APC & Industry Use - Case

Phillip TerleskSales Executive


Rockwell Improves Manufacturing Processes

Enhance Profitability through:- Improve Product Quality

Minimize variabilityReduce deviation from

specifications

- Increase ProductionUnlock capacity Maximize

throughput

- Reduce Manufacturing CostsUse less energy per unit of outputMaximize yield

MPC Goal – High ROI, robust, operator friendly solutions that deliver long-term value


Analysis

Prediction

Control

Optimization

Soft Sensors

Model-based Applications Approach

A Hybrid Model explains or emulates

the behavior of a process.


Pavilion8 Model Predictive Control

21

Controller executes at 5 sec to 1 min intervals


Soft Sensors (Virtual Online Analyzers or VOA)

… neural networks can fit general non-linear

relationships

input

A input B

outpu

t

artificial neuron with weight parameters

VOA

Calcs

ProcessData

LabData

Product Quality

Process Parameter

Neural Networks Replace sparse, or infrequent, feedback from Lab or analyzer

RecircFeedFermRXN HHHH Heat and Material Balances

RXNHfEtOH Traditional Empirical Correlations


How APC Enables Operational Objectives

Minimize operational variance

DV CV

Transition effectively

CV

Follow operational plan

CV

SPECIFICATION OR LIMIT

BEFORE MODEL PREDICTIVE CONTROL

WITH MODEL PREDICTIVE CONTROLAND OPTIMIZATION

KE

Y T

AR

GE

TBENEFIT $

Reduce Variability 30 – 50%

Achieves Uplift - closer to spec or performance limit whilst managing the process within constraints and safety margins

The Business Value is Achieved by

“raising the bar”

23


Operator Interaction with a Standard Regulatory Control System

24

Process Lab

PID PIDPID PLC/DCS

?!?!? Step A,D,B,C


Operator interaction with aModel Predictive Control System

25

Process

Soft Sensor MPC

Lab

Pavilion8

PID PIDPID PLC/DCS

ProductionTarget


Milk Powder Processing

26

• Farm Cows

• Tankers / Rail

• Raw Milk Silo Storage

• Separation into skim milk and cream

• Standardization to specifications by combining skim milk, cream, and lactose or permeate

• Falling Film Evaporation

• Spray Drying

• Powder Packing


Plant Pax - Visualisation

ERPERP

MOM

SCADA

Controls & SafetyRo

ckwe

ll FT

Hist

oria

n -

Repo

rting

and

Too

ls

Receiving Area & Raw Milk Silos

Milk Separation into Skim Milk & Cream

Utilities Evaporation / Drying / Fluidbed

Packaging /Logistics/Mass Serialisation

Quality

Production Landscape Future Automation Landscape

Dairy Solution

CPGSuite

Standardization to specifications by combining skim milk, cream, and lactose or permeate / Milk Treatment

Pavilion Moisture Optimisation Powder Drying

Pavilion Fat / ProteinOptimisation

CPG Suite Labeling / Serialisation

Milk Treatment

Packaging

Plant Pax - Logix

28Copyright © 2013 Rockwell Automation, Inc. All rights reserved. 28

Scope for both Protein & Fat Optimisation & Pavilion8 Dryer & Evap MPC

Wholemilk Separation Pasteurization

Permeate / Lactose etc

Cream

ProcesScan™ FT

Product In8-15% solids

Product Out45 -55% solids

Cold Air

Hot Air

Hot Air

Powder Out

Solids In

HP Pumping Drying

Standardized buffer Storage

Butter Processing

Standardizing Streams

Rockwell - Protein & Fat Optimisation Solution

Pavilion8 Protein & Fat Optimisation Analysis – this overview

Rockwell’s MPC Solution-Dryer & Evap Optimization

Pavilion8 MPC Dryer & Evap Optimisation


Dairy Standardisation Solution

29

• Rockwell’s Pavilion8 Model Predictive Control (MPC) platform provides a closed loop standardising solution with superior targeting of final powder Fat and Protein composition.

• Minimising giveaway of protein and fat in the standardisation process optimises yield providing substantial financial benefit.


Dairy Standardisation Solution Performance and Visability

30


31

Moisture benefits, control performance & how hard moisture is pushed

Distribution curve comparison (mean & standard deviation) against baseline

Accepted moisture lab value against specification limit and controller target

Cp – how good is distribution within limits: Cpk – how centre is the distribution within limits

Standard deviation improvement against baseline

Downloadable & accepted moisture lab values report

A key Differentiator

Visualisation: Performance Metrics


Dairy Standardisation Solution Benefits

32

• Composition variability reduction of 50% or greater

• Tight compositional control allows fat and protein targets to be driven to the specification minimums.

• Superior final powder compositional targeting.

• Performance visualisation facilitates proactive decisions

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Driving Operational Performance by building Manufacturing Capability one step at a time…