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Enabling
Plant Performance Benchmarking
in a multi-site environment
Wim ten [email protected]
Bert [email protected]
Akzo Nobel – Atos Origin – Enabling Plant Performance Benchmarking 2
Agenda
• Introduction
• Business Challenge
• Solution Description
• Benefits
• Future Plans
Akzo Nobel – Atos Origin – Enabling Plant Performance Benchmarking 3
Introduction
• Akzo Nobel Base Chemicals BV
• Atos Origin Nederland BV
Introduction
Akzo Nobel – Atos Origin – Enabling Plant Performance Benchmarking 4
Akzo Nobel
• Activities in 80 countries
• Employing 62,000 people
• Consolidated revenues 2004 totals € 12.9
billion
• Headquarter Arnhem, the Netherlands
– Market-driven and technology-based
– Serving customers throughout the world with
healthcare products, coatings and chemicalsIntroduction – Akzo Nobel
Akzo Nobel – Atos Origin – Enabling Plant Performance Benchmarking 5
Akzo Nobel Base Chemicals BV
• Business Unit, headquarter Amersfoort, the Netherlands
• 2,000 employees
• € 800 million sales
• Produces Energy Cogeneration, Bulk Salt, Chlorine-alkali products and derivatives
• Our products play a vital role in a variety of industries and in many day-to-day articles like glass, textile, detergents, paper, plastics, pharmaceuticals and disinfectants.
Introduction – Akzo Nobel
Akzo Nobel – Atos Origin – Enabling Plant Performance Benchmarking 6
Akzo Nobel Base Chemicals BV
Production sites:
• 3 Energy Cogen
• 3 Bulk Salt
• 5 Chlorine
• 2 Ferro-Chlorine
Introduction – Akzo Nobel
Akzo Nobel – Atos Origin – Enabling Plant Performance Benchmarking 7
Production Outline
Introduction – Akzo Nobel
Akzo Nobel – Atos Origin – Enabling Plant Performance Benchmarking 8
Atos Origin
• A leading IT services company providing business consulting, systems integration and managed operations that improve the effectiveness of its clients’ businesses
• 2005 FY revenue € 5.5 bn
• Over 47,000 employees
• Presence in 40 countries
• Industry (Public Sector, Finance, Telecom/Media, Discrete mfg, PILS, Retail)
Introduction – Atos Origin
Akzo Nobel – Atos Origin – Enabling Plant Performance Benchmarking 9
Managed
Operations
51%
Systems
Integration
41%
Consulting
8%
(*) Of which 14%
is recurring
business
Atos Origin
Introduction – Atos Origin
Business Mix Geography Industry
(*) Including Transport
(**) Process Industry & Life Sciences
(*) Application Management
Public Sector
& Utilities
26%
Telecom
& Media
19%
Discrete
Manufacturing
12%
PILS (**) 8%
Finance
19%
Others (*)
6%Retail 10%
France
28%
UK
21%Benelux
21%
Germany + CE
10%
Italy 6%
Others 9%
Spain 5%
Akzo Nobel – Atos Origin – Enabling Plant Performance Benchmarking 10
Introduction – Atos Origin
Total Employees 47,700
North America
1,000Spain
4,800
Benelux
9,300France
12,400
Italy
3,100Asia/Pacific
2,000
UK
6,500
South America
1,300
Middle East &
Africa
500
Central Europe
2,600
North America
750Spain
5,400
Benelux
9,300France
14,000
Italy
2,900Asia/Pacific
2,500
UK
6,900
South America
1,700
Middle East &
Africa
500
Central Europe
3,750
Atos Origin
Akzo Nobel – Atos Origin – Enabling Plant Performance Benchmarking 11
Business Challenge
• What were our business issues?
• Where did we come from?
• What were our objectives?
• Where do we want to go?
Business Challenge
Akzo Nobel – Atos Origin – Enabling Plant Performance Benchmarking 12
What Were Our Business Issues?
• No harmonized definition of plant data
• Different legacy MES systems or none at all
• No uniformity on Production Accounting
• Manual transfers of production information
• No “bird’s-eye view” on overall performance
• No possibilities for plant benchmarking
• No common “manufacturing language”
Business Challenge – Business Issues
Akzo Nobel – Atos Origin – Enabling Plant Performance Benchmarking 13
Where Did We Start From?
Business Challenge – Point of departure
Chlorine
BIT
Chlorine
IRNChlorine
DZL
ABB EmersonHoneywell
Plant
DCS
ERP
Chlorine
HGL
Chlorine
RDM
Foxboro Foxboro
MES
SAP
PI3
Progres
Excel
Chlorine
SHL
Emerson
DeltaV
Excel
Navision
Fox-comFox-com
Emerson
RS/3
GermanyNetherlands Sweden
2002
Akzo Nobel – Atos Origin – Enabling Plant Performance Benchmarking 14
What Were Our Objectives?
• Replace Progres in NL (3 plants)
• Replace Navision in GE (2 plants)
• Harmonize all 6 chlorine plants on plant
information level (MES)
• Take into account:
– 2 old plants will be shutdown within 2 years
– 1 new plant will be started up within 1,5 years
Business Challenge – Objectives
Akzo Nobel – Atos Origin – Enabling Plant Performance Benchmarking 15
Why Did We Choose PI?
• Already present at 1 plant
• Used at other plants within Akzo Nobel
• Commercially available standard product
• Proven technology
• Numerous and proven interfacing possibilities
• Lowest TCO of alternatives
• Core business for supplier
Business Challenge – Why PI?
Akzo Nobel – Atos Origin – Enabling Plant Performance Benchmarking 16
Surprises During The Project
• Reorganization within Akzo Nobel:
– 3 BU’s (Energy, Salt and BC) were merged
– Scope became more extensive
• MCA plants of Functional Chemicals want
to join the Base Chemicals MES program
Business Challenge – Surprises
Akzo Nobel – Atos Origin – Enabling Plant Performance Benchmarking 17
New Challenge
• 3 Bulk Salt plants to add
• 3 Energy Cogeneration plants to add
• 2 MCA plants to add
• 2 additional SAP systems to merge
• 6 additional DCS systems to connect
• > 10 additional third party systems to connect
• 8 additional legacy systems to replace
• 1 additional country to take into account
Business Challenge – New Challenge
Akzo Nobel – Atos Origin – Enabling Plant Performance Benchmarking 18
Now Where Are We Starting From?
Business Challenge – New point of departure
Chlorine
BIT
Chlorine
IRNChlorine
DZL
ABB Emerson Honeywell
Plant
DCS
ERP
Chlorine
HGL
Chlorine
RDMSalt
DZL
ValmetHoney-
well
Salt
HGL
Salt
MGR
Energy
DZL
Energy
HGL
Energy
RDM
ABB Honey-
well
Honey-
wellFoxboroFoxboro Foxboro
MES
SAP BC SAP Salt SAP Energy
Progres
PI3
Progres
Excel PHD PHD SQL
Chlorine
SHL
MCA
SHL
Emerson
DeltaV
Excel
PI2 PHD Fox-com
Navision
Fox-comFox-com
Fisher
RS/3
2005
Germany Netherlands Sweden Netherlands Denmark Netherlands
MCA
HGL
Foxboro
PHD
SAP FC
Excel
Akzo Nobel – Atos Origin – Enabling Plant Performance Benchmarking 19
Where Do We Want To Go?
Business Challenge – Goal
Chlorine
BIT
Chlorine
IRNChlorine
DZL
ABB EmersonHoney-
well
Plant
DCS
ERP
MCA
DZL
Chlorine
RDMSalt
DZL
MetsoHoney-
well
Salt
HGL
Salt
MGR
Energy
DZL
Energy
HGL
Energy
RDM
ABB Honey-
well
Honey-
wellHoneywell
MES
Chlorine
SHL
MCA
SHL
Emerson
DeltaV
Emerson
RS/3
PI
SAP BC
Emerson
Germany Netherlands Sweden Netherlands Denmark Netherlands
2009
SAP FC
Akzo Nobel – Atos Origin – Enabling Plant Performance Benchmarking 20
Solution
• Central PI Server with high availability
• Local PI Interface Nodes (high availability)
• Local, but uniform, Production Accounting
• Local, but uniform, reporting
• Scripted (WXP) client software (PB, DL)
• As much as possible standard PI software
Solution
Akzo Nobel – Atos Origin – Enabling Plant Performance Benchmarking 21
Issues
• Finding a suitable solution for Production Accounting
• Multiple plants on 1 PI system
• Differences in language and culture
• Availability Akzo Nobel employees for MES projects
• Network load vs. capacity
• Connecting Process Control Layer to office LAN
• Parallel processing can take long
• What is the real truth: the old system or the new one?
Solution – Issues
Akzo Nobel – Atos Origin – Enabling Plant Performance Benchmarking 22
Issues
• Finding a suitable solution for Production
Accounting
Solution – Issues
Akzo Nobel – Atos Origin – Enabling Plant Performance Benchmarking 23
Issues – Finding A Suitable Solution
For Production Accounting
• Production Accounting consists of
– Daily and monthly calculations for:
• Consumed utilities and raw materials
• Produced chemicals
• Delivered chemicals to customers
• Inventory (tank levels tonnes of product)
– Daily and monthly reporting on the above
– Updating SAP with the above
Solutions – Issues – Production Accounting
Akzo Nobel – Atos Origin – Enabling Plant Performance Benchmarking 24
Issues – Finding A Suitable Solution
For Production Accounting
• PI ACE:
• Too complex programming for end-users
• Too much work-arounds needed
• Calculation sequence is not automatically managed
• PI Analysis Framework:
• Too much configuration needed for this purpose
• Too high TCO for this purpose
• But, still evaluating PI AF benefits for other purposes
Solutions – Issues – Production Accounting – Alternatives
Akzo Nobel – Atos Origin – Enabling Plant Performance Benchmarking 25
Issues – Finding A Suitable Solution
For Production Accounting
• Solution: Build something yourself
• Production Accounting Calculation Engine (PACE)
• Based on Microsoft tools and OSIsoft PI SDK
• Formulas stored in local database (MS Access)
• Using Access as a calculator
• Calculation results stored in PI Archives
• Reporting with Excel and DataLink
Solutions – Issues – Production Accounting
Akzo Nobel – Atos Origin – Enabling Plant Performance Benchmarking 26
Issues – Finding A Suitable Solution
For Production Accounting
• Benefits:
• Easy management of calculations by end-users
• Automatic management of calculation sequence
• Simple validation of results
• Easy manual changes and additions of data
• Simple possibilities for recalculations
• Free to change functionality
– (like adding Formula Change Management)
Solutions – Issues – Production Accounting
Akzo Nobel – Atos Origin – Enabling Plant Performance Benchmarking 27
Issues – How Were Other Issues
Solved• Short PB + DL reference manuals in local languages
• Agree upon tag naming convention and stick to it
• Implement PI security on tags and data (proxy)
• Prioritize network traffic for PI and improve band width
• Implement hardware firewalls to connect Process Control Layer to office LAN (but, still a burden)
• Fixed core project team for all rollout projects
• Workload shift from Akzo Nobel to Atos Origin
Solution – Other issues solved
Akzo Nobel – Atos Origin – Enabling Plant Performance Benchmarking 28
Products Used
• PI server software, including DAP
• PI interfaces: OPC (2), PI-to-PI (4), PHD (2),
RNI, DDE, ABB-IMS
• ProcessBook, DataLink, SDK
• Custom build interfaces: File Transfer, legacy
systems
• Custom build applications: PACE, Manual Input
Solution – Products used
Akzo Nobel – Atos Origin – Enabling Plant Performance Benchmarking 29
Solution – Examples
Overall
performance
overview
Solution – Example
Akzo Nobel – Atos Origin – Enabling Plant Performance Benchmarking 30
Solution – Examples
• Insights in consumptions, production and
deliveries
Akzo Nobel – Atos Origin – Enabling Plant Performance Benchmarking 31
Solution – Examples
• Insights in stocks
Akzo Nobel – Atos Origin – Enabling Plant Performance Benchmarking 32
Solution – Examples
• Production Accounting, Formulas
Akzo Nobel – Atos Origin – Enabling Plant Performance Benchmarking 33
Solution – Examples
• Production Accounting, Calculation
Akzo Nobel – Atos Origin – Enabling Plant Performance Benchmarking 34
Where Are We Now?
Business Challenge – Current Status
Chlorine
BIT
Chlorine
IRNChlorine
DZL
ABB EmersonHoney-
well
Plant
DCS
ERP
MCA
DZL
Chlorine
RDMSalt
DZL
MetsoHoney-
well
Salt
HGL
Salt
MGR
Energy
DZL
Energy
HGL
Energy
RDM
ABB Honey-
well
Honey-
wellHoneywell
MES
Chlorine
SHL
MCA
SHL
Emerson
DeltaV
Emerson
RS/3
PI
SAP BC
Emerson
Germany Netherlands Sweden Netherlands Denmark Netherlands
2006
SAP FC
Akzo Nobel – Atos Origin – Enabling Plant Performance Benchmarking 35
Benefits, So Far
• Harmonized definition of plant data
• Uniformity on Production Accounting
• Common “manufacturing language”
• Excellent possibilities for plant benchmarking
• Better view on overall performance
• Better view on consumptions, stocks and deliveries
• Improved Production Planning
Benefits – Current Status
Akzo Nobel – Atos Origin – Enabling Plant Performance Benchmarking 36
Opportunities
• First step for improvements is made
• People are experiencing the power of PI
• New possibilities will be discovered
Benefits – Opportunities
Akzo Nobel – Atos Origin – Enabling Plant Performance Benchmarking 37
Future Plans
• RtWebParts to make PI data available from
every seat at every site
• PI Batch
• PI SQC within ProcessBook
• Investigate feasibility of integrating PI with
SAP Plant Maintenance
• Investigate feasibility of other opportunities still to
be found
Future Plans
Akzo Nobel – Atos Origin – Enabling Plant Performance Benchmarking 38
Conclusion
• We have certainly reached value now
• We expect to get more value over time
Conclusion
