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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…
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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!
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7 Empowering Business in Real Time. © Copyright 2009, OSIsoft Inc. All rights Reserved.
…easy as PI -or- PI is so easy a…
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8 Empowering Business in Real Time. © Copyright 2009, OSIsoft Inc. All rights Reserved.
OSIsoft Collaboration
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9 Empowering Business in Real Time. © Copyright 2009, OSIsoft Inc. All rights Reserved.
Contest example… “Value Now”
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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”
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11 Empowering Business in Real Time. © Copyright 2009, OSIsoft Inc. All rights Reserved.
Contest example… “Value Now”
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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”
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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”
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14 Empowering Business in Real Time. © Copyright 2009, OSIsoft Inc. All rights Reserved.
Contest example… “Value Now”
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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…
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17 Empowering Business in Real Time. © Copyright 2009, OSIsoft Inc. All rights Reserved.
Future Drives… “Value over Time”
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18 Empowering Business in Real Time. © Copyright 2009, OSIsoft Inc. All rights Reserved.
Future Drives… “Value over Time”
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19 Empowering Business in Real Time. © Copyright 2009, OSIsoft Inc. All rights Reserved.
Wrap-up… “Value Now, Value over Time”
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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