Global PI SystemGlobal PI System

Dow Corning CorporationDow Corning Corporation

Doug LooseDoug Loose

Global Process Information ManagerGlobal Process Information Manager

Dow Corning Profile SPCDow Corning Profile SPC

usdcchd3@ibmmail.com

IntroductionIntroduction

Dean Brown - PI System AdministratorDean Brown - PI System Administrator Al McInally - Sr. Manufacturing EngineerAl McInally - Sr. Manufacturing Engineer

PROFILE STATISTICAL PROCESS CONTROLPROFILE STATISTICAL PROCESS CONTROL The Profile SPC real-time engine extends

the power of statistical process control to BATCH processes.

Instead of comparing values of a variable which should be held constant, such as product test data, Profile SPC determines the process parameter profiles versus time into the batch.

PROFILE STATISTICAL PROCESS CONTROL(Continued)PROFILE STATISTICAL PROCESS CONTROL(Continued)

This yields guidelines (a center line and upper and lower control limits that are a function of time into the batch).

This allows many capabilities: Production personnel can use this to assure that critical parameters are within their SPC profiles, i.e. they are normal batches.

PROFILE STATISTICAL PROCESS CONTROL(Continued)PROFILE STATISTICAL PROCESS CONTROL(Continued)

It “sees” problems which can’t be seen by the usual process monitoring tools.

It allows mistakes to be corrected before a product is ruined.

The method employs Deming’s methods REAL TIME to processes and is visual and intuitive.

Dow Corning Profile SPCDow Corning Profile SPC

Characterization of Current Systems

Benefits

Process CharacteristicsProcess Characteristics

Single recipe batch operations Batch times from 8 hours to 2

days to 3 weeks Classic continuous distillation

columns Common feed systems

Midland Plant - ProcessMidland Plant - ProcessControl System NetworkControl System Network

PCU5 PCU6 PCU1

PCU2

PCU2 DCU3

DCU3

PCU4DCU1

DCU1

ENG

LOC DCTDCT DCTDCT DCTDCTDCTDCT DCTDCT DCTDCT DCTDCT DCTDCT

DOC

GDU GDU

DCU2

DCU2

DCTDCT DCTDCT

PCU3

DCTDCT

* Four Separate Display Highways

* Redundant Process Highways

* Five Control Rooms

* Eleven Process Buildings

DMC1DMC1 XDC1XDC1XDC2XDC2 XDC3XDC3

Bridge Plant LAN

PCU1

ENG

DCTDCT

PINetNode

BenefitsBenefits

Provides in depth process analysis of process variables

Reduce Quality testing- parametric acceptance

Reduce Cycle-time

Activate/Deactivate SPC Groups

Sybase

Server

PI

Server

Perform SPC on running SPC groups

Retrieve Configuration Updates

Generate Status File

PSPC.EXE

Previous run lot # & start times (on

activation)

New run end time (on deactivation)

New run start time & lot # (on activation)

Sample trigger tags for all SPC groups

PSPC_STATUS.TXT

Main processing Loop

Raw tag values for previous runs @ N minutes into the run

Control limits calc’d @ N mintues into previous run

Resultant tag values for current run @ N minutes into the run

Control limits calc’d @ N minutes into current run (to be used on next run)

New, modified or deleted buildings, SPC

groups or points Resultant tags to be

createdRecord status updates

& deletes

Interested ClientsInterested Clients

I would like to re-iterate that Dow Corning I would like to re-iterate that Dow Corning is working with OSI to have Profile SPC is working with OSI to have Profile SPC incorporated into OSI’s SQC package in a incorporated into OSI’s SQC package in a future release. We would like to encourage future release. We would like to encourage anyone that is interested in this concept to anyone that is interested in this concept to pass this on to Mark Hughes at OSI.pass this on to Mark Hughes at OSI.

Profile SPC AdministratorAnd The User

PI System AdministratorPI System Administrator

Dean E. BrownDean E. Brown

How Does It Work? Opening ScreenOpening Screen LogIn To SyBase (MS SQL in future versions)LogIn To SyBase (MS SQL in future versions) Setting Up A BuildingSetting Up A Building Setting Up An SPC Group for the BuildingSetting Up An SPC Group for the Building Requires a Trigger Tag (From 0 to 1)Requires a Trigger Tag (From 0 to 1) Setting Up SPC “Resultants” to be AnalyzedSetting Up SPC “Resultants” to be Analyzed A Process on the PI HomeNode does it’s work.A Process on the PI HomeNode does it’s work. ProcessBook is the Tool for Viewing the ProcessBook is the Tool for Viewing the

ResultantsResultants History Can Be ChangedHistory Can Be Changed

Opening Screen

LogIn To SyBase (MS SQL in future versions)

Setting Up A Building

Building/Area

Setting Up An SPC Group for the Building

SPC Group Definitions

Requires a Trigger Tag (From 0 to 1)

Trigger Tag Is A Key

Setting Up SPC “Resultants” to be Analyzed

Specific Process Tags

A Process on the PI HomeNode does it’s work.

0 - 1 - 0 0 - 1 - 0

0 - 1 - 0

0 - 1 - 0

0 - 1 - 0

0 - 1 - 0

0 - 1 - 0

0 - 1 - 0

ProcessBook is the Tool for Viewing the Resultants

No Alarm

No Alarm

Over Range

Over Center

History Can Be Changed

Now Users Make Product in a Consistent Fashion

Profile S P C

Al McInallyAl McInally

Dow Corning CorpDow Corning Corp..

K e tt le T e m p (C )

4 8 9 5 M T O K e ttle T e m p -X U4 8 9 5 M T O K e ttle T e m p -X C4 8 9 5 M T O K e ttle T e m p -X L4 8 9 5 M T O K e ttle T e m p -X R

6 /2 6 /9 5 1 0 :3 0 :0 0 A M 6 /2 6 /9 5 0 2 :0 0 :0 0 P M3 .5 0 H o u r(s )

B G :T T 5 5 7 .X U

U C L B G :T T 5 5 7 .X C

C L B G :T T 5 5 7 .X L

L C L B G :T T 5 5 7 .X R

X V a lu e

6 0

8 0

1 0 0

1 2 0

1 4 0

4 0

1 5 01 1 9 .9 0 6 3

1 0 8 .6 3 7 8

9 7 .3 6 9 4

1 3 9 .4 1 0 8

B G :T T 5 5 7 .X U

U C L B G :T T 5 5 7 .X C

C L B G :T T 5 5 7 .X L

L C L B G :T T 5 5 7 .X R

X V a lu e

o v e r u c l

Kettle Temp (C)

4895 MTO Kettle Temp -XU4895 MTO Kettle Temp -XC4895 MTO Kettle Temp -XL4895 MTO Kettle Temp -XR

6/26/95 10:43:33 AM 6/27/95 09:40:49 AM22.95 Hour(s)

BG:TT 557.XU

UCL BG:TT 557.XC

CL BG:TT 557.XL

LCL BG:TT 557.XR

X Value

20

40

60

80

100

120

140

160

180

0

200TriggerTerm

TriggerTerm

TriggerTerm

TriggerTerm

BG:TT 557.XU

UCL BG:TT 557.XC

CL BG:TT 557.XL

LCL BG:TT 557.XR

X Value

n o a la r m

Kettle Temp (C)

6/26/95 10:30:00 AM 6/26/95 02:00:00 PM

UCL

CL

LCL

X Value

60

80

100

120

40

150 119.9063

108.6378

97.3694

139.4108

UCL

CL

LCL

X Value

Overhead Vapor Temp (C)

6/26/95 10:30:00 AM 6/26/95 02:00:00 PM

UCL

CL

LCL

X Value

30

40

50

60

70

80

90

100

18

115 73.3523

46.2297

19.1070

72.8367

UCL

CL

LCL

X Value

Vacuum (MMHG)

6/26/95 10:30:00 AM 6/26/95 02:00:00 PM

UCL

CL

LCL

X Value

40

60

80

100

120

140

160

10

200 168.8660

135.7073

102.5515

19.7633

UCL

CL

LCL

X Value

Receiver Level (GALS)

6/26/95 10:30:00 AM 6/26/95 02:00:00 PM

UCL

CL

LCL

X Value

200

300

50

460 245.9173

103.8637

Under Range

455.9980

UCL

CL

LCL

X Value

Under LCLOver UCL

Over UCL

Over UCL

output to vac valv

6/26/95 10:30:00 AM 6/26/95 02:00:00 PM

BG:PIC553.OT

50

35

6039.5189BG:PIC553.OT

Kettle Temp (C)

5617 203 C12 KET TEMP -XU5617 203 C12 KET TEMP -XC5617 203 C12 KET TEMP -XL5617 203 C12 KET TEMP -XR

9/29/95 00:41:08 AM 9/29/95 04:25:16 AM3.74 Hour(s)

BG:203CTT.XU

UCL BG:203CTT.XC

CL BG:203CTT.XL

LCL BG:203CTT.XR

X Value

135

140

145

150

155

160

165

170

131.0078

176.1046161.9503

150.7405

139.5367

139.4818

BG:203CTT.XU

UCL BG:203CTT.XC

CL BG:203CTT.XL

LCL BG:203CTT.XR

X Value

u n d e r lc l

Kettle Temp (C)

5617 203 C12 KET TEMP -XU5617 203 C12 KET TEMP -XC5617 203 C12 KET TEMP -XL5617 203 C12 KET TEMP -XR

1/3/96 07:23:00 AM 1/3/96 02:04:00 PM6.68 Hour(s)

BG:203CTT.XU

UCL BG:203CTT.XC

CL BG:203CTT.XL

LCL BG:203CTT.XR

X Value

20

40

60

80

100

120

140

160

180

0

200TriggerTerm

TriggerTerm

TriggerTerm

TriggerTerm

BG:203CTT.XU

UCL BG:203CTT.XC

CL BG:203CTT.XL

LCL BG:203CTT.XR

X Value

n o a la rm

Windows Into Processes

SQC (after the fact)

Profile RTSPCreal time (RT)

Mass BalSPC (RT)

Cyc.TimeSPC (RT)

Energy BalSPC (RT)

On line GC(RT)

At line data (RT) ??????????

process

SPC on continuousprocess parameters(RT)

RT standsfor real time

TIME P TP V FL V TP LVL18:00 55 87 918 45 119:00 52 101 1528 71 1220:00 50 107 581 75 2021:00 50 119 1468 87 3522:00 49 127 1404 95 5023:00 49 138 1494 103 670:00 51 145 428 109 791:00 50 149 0 102 88

TIME P TP V FL V TP LVL13:00 52 174 77 41 114:00 49 504 104 74 1915:00 team meeting16:00 49 1437 122 90 4117:00 49 1350 128 96 5218:00 51 780 137 101 6619:00 49 1295 148 111 8320:00 50 0 149 110 90

TIME P TP V FL V TP LVL10:00 64 97 630 41 111:00 46 108 1762 79 2112:00 48 117 1907 84 3113:00 51 131 553 95 4914:00 51 137 1907 100 5915:00 50 147 504 107 7916:00 50 149 1 103 85

VS P C c h a r t

0

0 . 0 2

0 . 0 4

0 . 0 6

0 . 0 8

1 3 5 7 9 11 13 15 17

R a n g e C h a r t

0

0 . 0 1

0 . 0 2

0 . 0 3

0 . 0 4

1 3 5 7 9 11 13

15

Volatiles

1

2 3

Kettle Temperature (C)

UCL

CL

LCL

X Value

90

100

110

120

130

140

70

160 TriggerTerm

TriggerTerm

TriggerTerm

TriggerTerm

UCL

CL

LCL

X Value

Kettle Pressure (mmHg)

UCL

CL

LCL

X Value

40

50

60

70

80

25

90 TriggerTerm

TriggerTerm

TriggerTerm

TriggerTerm

UCL

CL

LCL

X Value

Receiver Level (gals)

UCL

CL

LCL

X Value 40

60

80

20

110 TriggerTerm

TriggerTerm

TriggerTerm

TriggerTerm

UCL

CL

LCL

X Value

Overhead Flow Rate (scfh)

1000

1500

2000

2500

0

3500 TriggerTermTriggerTermTriggerTermTriggerTerm

No Alarm

No Alarm

No Alarm

Under Center

Overhead Flow Temp (C)

4/10/96 05:21:00 PM 4/11/96 01:51:00 AM

UCL

CL

LCL

X Value

40

60

80

0

120 TriggerTerm

TriggerTerm

TriggerTerm

TriggerTerm

UCL

CL

LCL

X Value No Alarm

Batch 1

Kettle Temperature (C)

UCL

CL

LCL

X Value

90

100

110

120

130

140

70

160 TriggerTerm

TriggerTerm

TriggerTerm

TriggerTerm

UCL

CL

LCL

X Value

Kettle Pressure (mmHg)

UCL

CL

LCL

X Value

40

45

50

55

60

65

70

30

80 TriggerTerm

TriggerTerm

TriggerTerm

TriggerTerm

UCL

CL

LCL

X Value

Receiver Level (gals)

UCL

CL

LCL

X Value 40

60

80

20

110 TriggerTerm

TriggerTerm

TriggerTerm

TriggerTerm

UCL

CL

LCL

X Value

Overhead Flow Rate (scfh)

1000

1500

2000

2500

0

3500 TriggerTermTriggerTermTriggerTermTriggerTerm

No Alarm

No Alarm

Under 1Sigma

Under Center

Overhead Flow Temp (C)

4/16/96 12:42:00 PM 4/16/96 08:56:00 PM

UCL

CL

LCL

X Value

40

60

80

0

120 TriggerTerm

TriggerTerm

TriggerTerm

TriggerTerm

UCL

CL

LCL

X Value Under 1Sigma

Batch 2

Kettle Temperature (C)

UCL

CL

LCL

X Value

90

100

110

120

130

140

70

160 151.3629

149.3672

147.3716

148.7388

UCL

CL

LCL

X Value

Kettle Pressure (mmHg)

UCL

CL

LCL

X Value

40

45

50

55

60

65

70

30

80 51.6068

49.8520

48.0972

49.9969

UCL

CL

LCL

X Value

Receiver Level (gals)

UCL

CL

LCL

X Value 40

60

80

20

110 99.7705

87.4556

75.1413

84.0017

UCL

CL

LCL

X Value

Overhead Flow Rate (scfh)

1000

1500

2000

0

3000 415.796492.3154Under Range0.0000

No Alarm

No Alarm

No Alarm

No Alarm

Overhead Flow Temp (C)

4/18/96 08:23:00 AM 4/18/96 04:23:00 PM

UCL

CL

LCL

X Value

40

60

80

0

120 111.4637

104.3654

97.2715

99.0020

UCL

CL

LCL

X Value No Alarm

Batch 3

No AlarmUnder CenterNo Alarm No Alarm

RTSPC

ket tmp ket pres ovhd vap ams ctlr ot ams fl rt

No Alarm No Alarm No Alarm No Alarm No Alarm

RTSPC4820 230 AMS Add

4820 230 Eth Add RTSPCket tmp ket pres eth fl rt srv h2o cv open'g

No Alarm No Alarm No Alarm No Alarm

ket tmp ket pres ovhd vp tmprec lvl

4820 230 stripket tmp ket pres ovhd ft vap tmp rec lvlNo AlarmOver UCL Over WL Under CenterUnder Range

RTSPC

4895 MTO

5617 203 ams addket tmp ket pres vap fl ams fl #/hr ams cntlr otpt

No Alarm No Alarm No Alarm No Alarm No Alarm

RTSPC

5617 203 C12 addket tmp vap tmp C12 fl rt

No Alarm No Alarm No Alarm

RTSPC

5617 203 Stripket tmp ket pres vap fl vap tmp rec lv

RTSPC

Under LCL No Alarm No Alarm No Alarm No Alarm

Product A

Product B

Product C

Prod. D

Prod. E

Product F

Prod. G

Viscosity Problems

Glycol Loading

Siloxane Loading

IPA Loading

Heat Phase

Loading Phase

Exotherm Temp

Exotherm Pressure

Strip Phase

Strip Temp

Strip Vacuum

Strip Vapor Flow

Strip Vapor Temp

Receiver Level

No Alarm

No Alarm

Under LCL

No Alarm

No Alarm

No Alarm

No Alarm

No Alarm

No Alarm

No Alarm

FF-400 in 19840

Loading RTSPC

Heat RTSPC

Strip RTSPC

Go To Kettle Overview 26,40,60

Exotherm Vapor Flow No Alarm

FF-400 GLYCOL LOADING

Glycol Loading Rate

20

30

40

0

55 TriggerTermTriggerTermTriggerTermTriggerTerm

Siloxane Loading Rate

10

20

0

35 TriggerTermTriggerTermTriggerTermTriggerTerm

IPA Loading Rate

10

2

19 TriggerTermTriggerTermTriggerTermTriggerTerm

Glycol Loading, Tk Level

20

30

0

45 TriggerTermTriggerTermTriggerTermTriggerTerm

Siloxane Loading, Tk Level

40

50

60

25

75 TriggerTermTriggerTermTriggerTermTriggerTerm

IPA Loading, Tk Level

75

67

82 TriggerTermTriggerTermTriggerTermTriggerTerm

Go To Kettle Overview 26,40,60Go To FF400 RTSPC Overview

FF-400 HEAT PHASEExotherm Temp

6/10/97 01:50:18 PM 6/10/97 05:02:22 PM3.20 Hour(s)

AB:FF400R.XC

AB:FF400R.XL

AB:FF400R.XR

AB:FF400R.XU80

90

100

65

115TriggerTerm

TriggerTerm

TriggerTerm

TriggerTerm

AB:FF400R.XC

AB:FF400R.XL

AB:FF400R.XR

AB:FF400R.XU

Exotherm Pressure

6/10/97 01:50:18 PM 6/10/97 05:02:22 PM3.20 Hour(s)

AB:FF400E.XC

AB:FF400E.XL

AB:FF400E.XR

AB:FF400E.XU780

800

820

840

750

870TriggerTerm

TriggerTerm

TriggerTerm

TriggerTerm

AB:FF400E.XC

AB:FF400E.XL

AB:FF400E.XR

AB:FF400E.XU

Go To Kettle Overview 26,40,60Go To FF400 RTSPC Overview

Exotherm Vapor Flow

FF-400 Exotherm Vapor F-XCFF-400 Exotherm Vapor F-XLFF-400 Exotherm Vapor F-XRFF-400 Exotherm Vapor F-XU

6/10/97 01:50:18 PM 6/10/97 05:02:22 PM3.20 Hour(s)

AB:FF40EV.XC

AB:FF40EV.XL

AB:FF40EV.XR

AB:FF40EV.XU

1000

2000

0

3000TriggerTerm

TriggerTerm

TriggerTerm

TriggerTerm

AB:FF40EV.XC

AB:FF40EV.XL

AB:FF40EV.XR

AB:FF40EV.XU

Strip Temp

100

120

70

160 TriggerTermTriggerTermTriggerTermTriggerTerm

Strip Vacuum

200

400

600

0

800 TriggerTermTriggerTermTriggerTermTriggerTerm

Strip Vapor Temp

90

100

110

75

130 TriggerTermTriggerTermTriggerTermTriggerTerm

Strip Vapor FlowAB:FF400F.XC

AB:FF400F.XL

AB:FF400F.XR

AB:FF400F.XU

400

600

800

1000

1200

0

1600TriggerTerm

TriggerTerm

TriggerTerm

TriggerTerm

AB:FF400F.XC

AB:FF400F.XL

AB:FF400F.XR

AB:FF400F.XU

Receiver LevelAB:FF400L.XC

AB:FF400L.XL

AB:FF400L.XR

AB:FF400L.XU

10

20

30

40

50

0

60TriggerTerm

TriggerTerm

TriggerTerm

TriggerTerm

AB:FF400L.XC

AB:FF400L.XL

AB:FF400L.XR

AB:FF400L.XU

FF-400 STRIP PHASE Go To Kettle Overview 26,40,60Go To FF400 RTSPC Overview

Profile S P C

Al McInallyAl McInally

Dow Corning Corp.Dow Corning Corp.

InterestedInterested

I would like to re-iterate that Dow I would like to re-iterate that Dow Corning is working with OSI to Corning is working with OSI to have Profile SPC incorporated into have Profile SPC incorporated into OSI’s SQC package in a future OSI’s SQC package in a future release. We would like to release. We would like to encourage anyone that is interested encourage anyone that is interested in this concept to pass this on to in this concept to pass this on to Mark Hughes at OSIMark Hughes at OSI..