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Copyright © 2011 Rockwell Automation, Inc. All rights reserved. Insert Photo Here Rockwell Automation Process Solutions User Group (PSUG) November 14-15, 2011 Chicago, IL – McCormick Place West Maximizing Process Efficiency Using Golden Batch Analysis Michael Lohmeyer / Grantek Systems

Maximizing Process Efficiency Using Golden Batch Analysis · Title: Microsoft PowerPoint - CS17_Grantek_FINAL [Compatibility Mode] Author: tcrichar Created Date: 1/5/2012 9:11:42

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Page 1: Maximizing Process Efficiency Using Golden Batch Analysis · Title: Microsoft PowerPoint - CS17_Grantek_FINAL [Compatibility Mode] Author: tcrichar Created Date: 1/5/2012 9:11:42

Copyright © 2011 Rockwell Automation, Inc. All rights reserved.

Insert Photo Here

Rockwell Automation

Process Solutions User Group (PSUG)

November 14-15, 2011

Chicago, IL – McCormick Place West

Maximizing Process

Efficiency Using

Golden Batch Analysis

Michael Lohmeyer / Grantek Systems

Page 2: Maximizing Process Efficiency Using Golden Batch Analysis · Title: Microsoft PowerPoint - CS17_Grantek_FINAL [Compatibility Mode] Author: tcrichar Created Date: 1/5/2012 9:11:42

Abstract

Copyright © 20011 Rockwell Automation, Inc. All rights reserved.

• Many batches are processed with limited or no real time visibility of adherence to ideal process parameters.

• Your operators can, and should, know how the current batch is progressing compared to a golden batch.

• Grantek Systems will present the Golden Batch planning board, and also present a Current Batch vs. Golden Batch comparison in real-time.

Page 3: Maximizing Process Efficiency Using Golden Batch Analysis · Title: Microsoft PowerPoint - CS17_Grantek_FINAL [Compatibility Mode] Author: tcrichar Created Date: 1/5/2012 9:11:42

Agenda

Copyright © 2011 Rockwell Automation, Inc. All rights reserved.

• Presentation Outline

• Define a Terminology

• Grantek Overview

• Issues in Batching

• Components of the Golden Batch Tool

• Setting up a Batch with the Golden Batch Tool

• Running a Batch with the Golden Batch Tool

Page 4: Maximizing Process Efficiency Using Golden Batch Analysis · Title: Microsoft PowerPoint - CS17_Grantek_FINAL [Compatibility Mode] Author: tcrichar Created Date: 1/5/2012 9:11:42

Presentation Outline

1. Today we will discuss the “Golden Batch” for a recipe.

o How to derive the Golden Batch for recipes from historical data,

o How to enable their operators to manage their current batch vs. the Golden Batch.

2. We will also discuss differences between a Golden Batch and a Best Batch.

3. We will understand that real time comparison of your current batch vs. Golden Batch is made possible by:

o Displaying, real time, process performance of current batch to Golden Batch

o Enabling your operators to adjust as needed, with real time information

Copyright © 2011 Rockwell Automation, Inc. All rights reserved.

Page 5: Maximizing Process Efficiency Using Golden Batch Analysis · Title: Microsoft PowerPoint - CS17_Grantek_FINAL [Compatibility Mode] Author: tcrichar Created Date: 1/5/2012 9:11:42

Copyright © 2011 Rockwell Automation, Inc. All rights reserved.

Grantek Systems’ Golden Batch Tool

The Planning Board – Enabling you to BUILD a Golden Batch

Page 6: Maximizing Process Efficiency Using Golden Batch Analysis · Title: Microsoft PowerPoint - CS17_Grantek_FINAL [Compatibility Mode] Author: tcrichar Created Date: 1/5/2012 9:11:42

• Run Time Viewer – Enabling you to achieve a Golden Batch

Copyright © 2011 Rockwell Automation, Inc. All rights reserved.

Grantek Systems’ Golden Batch Tool

Page 7: Maximizing Process Efficiency Using Golden Batch Analysis · Title: Microsoft PowerPoint - CS17_Grantek_FINAL [Compatibility Mode] Author: tcrichar Created Date: 1/5/2012 9:11:42

Grantek Systems’ Golden Batch Tool

• The Rockwell Automation tools that make this possible are:

Copyright © 2011 Rockwell Automation, Inc. All rights reserved.

Page 8: Maximizing Process Efficiency Using Golden Batch Analysis · Title: Microsoft PowerPoint - CS17_Grantek_FINAL [Compatibility Mode] Author: tcrichar Created Date: 1/5/2012 9:11:42

Grantek Systems Corporate Overview

• Grantek Systems is the only Rockwell Automation

Solution Provider in the world certified at all levels:

• Founded in 1980

• 125+ employees

• Principle Offices

– Chicago

– Allentown, PA

– Toronto

– Montreal

• Leading provider of Business Intelligence,

Manufacturing Intelligence, and Automation Solutions

for the for the Food and Bev, and Life Sciences

Industries.Copyright © 2011 Rockwell Automation, Inc. All rights reserved.

EnterpriseEnterpriseEnterpriseEnterprise

Grantek is the ONLY Rockwell Automation

Solution Provider certified at all levels!

Page 9: Maximizing Process Efficiency Using Golden Batch Analysis · Title: Microsoft PowerPoint - CS17_Grantek_FINAL [Compatibility Mode] Author: tcrichar Created Date: 1/5/2012 9:11:42

Grantek Systems Corporate Overview

• Grantek Systems is the only Solution Provider in the world

that Rockwell Automation has certified at all levels:

• Michael Lohmeyer

– Regional Sales Manager

– Oak Brook, IL, Office

Copyright © 2011 Rockwell Automation, Inc. All rights reserved.

EnterpriseEnterpriseEnterpriseEnterprise

Grantek is the ONLY Rockwell Automation

Solution Provider certified at all levels!

Page 10: Maximizing Process Efficiency Using Golden Batch Analysis · Title: Microsoft PowerPoint - CS17_Grantek_FINAL [Compatibility Mode] Author: tcrichar Created Date: 1/5/2012 9:11:42

Grantek Systems Clients

Copyright © 2011 Rockwell Automation, Inc. All rights reserved.

World Class Global Manufacturers

Page 11: Maximizing Process Efficiency Using Golden Batch Analysis · Title: Microsoft PowerPoint - CS17_Grantek_FINAL [Compatibility Mode] Author: tcrichar Created Date: 1/5/2012 9:11:42

Leveraging Information in Batching

• Manufacturers often experience differences in batches of the same recipe, while run on the same equipment. These differences are often either:– Batch Quality

– Batch time

• Analyzing these issues with out a real time operator

tool is often a “rear view mirror” exercise.– Interesting, but ……….

• Grantek has developed a tool that enables you to build a Golden Batch from your historical best phases.– More than just your “best batch”.

– You will build the Golden Batch from your best phases.

Copyright © 2011 Rockwell Automation, Inc. All rights reserved.

Page 12: Maximizing Process Efficiency Using Golden Batch Analysis · Title: Microsoft PowerPoint - CS17_Grantek_FINAL [Compatibility Mode] Author: tcrichar Created Date: 1/5/2012 9:11:42

Grantek Systems’ Golden Batch Tool

• Do you find yourself asking question like:

• Why did a batch take 30% longer on 3rd shift vs.

1st shift?

• Why did we scrap or rework 8 batches in October?

• Should it really take 20 minutes for the hand add step?

• Do we really need to mix for 14 minutes?

Copyright © 2011 Rockwell Automation, Inc. All rights reserved.

Page 13: Maximizing Process Efficiency Using Golden Batch Analysis · Title: Microsoft PowerPoint - CS17_Grantek_FINAL [Compatibility Mode] Author: tcrichar Created Date: 1/5/2012 9:11:42

Grantek Systems’ Golden Batch Tool

• What is a Golden Batch - is it really attainable in my plant?

• How do my operators achieve it?

– For a recipe, your process engineer builds a batch based on the best phases that your plant has ever done.

– You have set the bar at an attainable height. Your plant has really performed at this level.

Copyright © 2011 Rockwell Automation, Inc. All rights reserved.

Page 14: Maximizing Process Efficiency Using Golden Batch Analysis · Title: Microsoft PowerPoint - CS17_Grantek_FINAL [Compatibility Mode] Author: tcrichar Created Date: 1/5/2012 9:11:42

Grantek Systems’ Golden Batch Tool

• Grantek’s Golden Batch Tool will:

• Enable you to build the Golden Batch from the best

performance your plant has done on individual phases

• Enable your operator with real time tracking of the

current batch performance against the Golden Batch.

• Enable your process engineer to mine process data

easily for review of recent batch performances vs.

Golden Batch.

Copyright © 2011 Rockwell Automation, Inc. All rights reserved.

Page 15: Maximizing Process Efficiency Using Golden Batch Analysis · Title: Microsoft PowerPoint - CS17_Grantek_FINAL [Compatibility Mode] Author: tcrichar Created Date: 1/5/2012 9:11:42

Grantek Systems’ Golden Batch Tool

• Value of the Golden Batch Tool.

Copyright © 2011 Rockwell Automation, Inc. All rights reserved.

Page 16: Maximizing Process Efficiency Using Golden Batch Analysis · Title: Microsoft PowerPoint - CS17_Grantek_FINAL [Compatibility Mode] Author: tcrichar Created Date: 1/5/2012 9:11:42

Grantek Systems’ Golden Batch Tool

• Before running a batch.......imagine the value of your

process engineer mining your batch journal for the

best phases ever run in your plant on that recipe...and

building the Golden Batch!

Copyright © 2011 Rockwell Automation, Inc. All rights reserved.

Page 17: Maximizing Process Efficiency Using Golden Batch Analysis · Title: Microsoft PowerPoint - CS17_Grantek_FINAL [Compatibility Mode] Author: tcrichar Created Date: 1/5/2012 9:11:42

Grantek Systems’ Golden Batch Tool

• While running a batch...imagine the value of your

operator comparing each phase with the “best phase”

your plant has ever done!

Copyright © 2011 Rockwell Automation, Inc. All rights reserved.

Page 18: Maximizing Process Efficiency Using Golden Batch Analysis · Title: Microsoft PowerPoint - CS17_Grantek_FINAL [Compatibility Mode] Author: tcrichar Created Date: 1/5/2012 9:11:42

Grantek Systems’ Golden Batch Tool

• On a regular basis.......imagine the value of your

process engineer mining your recent batches / phases

and looking for anomalies. E.g. Excessive time for

manual ingredient addition, etc.

Copyright © 2011 Rockwell Automation, Inc. All rights reserved.

Page 19: Maximizing Process Efficiency Using Golden Batch Analysis · Title: Microsoft PowerPoint - CS17_Grantek_FINAL [Compatibility Mode] Author: tcrichar Created Date: 1/5/2012 9:11:42

Grantek Systems’ Golden Batch Tool

• Components of the Golden Batch Tool.

Copyright © 2011 Rockwell Automation, Inc. All rights reserved.

Page 20: Maximizing Process Efficiency Using Golden Batch Analysis · Title: Microsoft PowerPoint - CS17_Grantek_FINAL [Compatibility Mode] Author: tcrichar Created Date: 1/5/2012 9:11:42

Grantek Systems’ Golden Batch Tool

• The Golden Batch Tool

• Let’s examine the components:

Copyright © 2011 Rockwell Automation, Inc. All rights reserved.

Page 21: Maximizing Process Efficiency Using Golden Batch Analysis · Title: Microsoft PowerPoint - CS17_Grantek_FINAL [Compatibility Mode] Author: tcrichar Created Date: 1/5/2012 9:11:42

Grantek Systems’ Golden Batch Tool

• Setting up a Batch.

Copyright © 2011 Rockwell Automation, Inc. All rights reserved.

Page 22: Maximizing Process Efficiency Using Golden Batch Analysis · Title: Microsoft PowerPoint - CS17_Grantek_FINAL [Compatibility Mode] Author: tcrichar Created Date: 1/5/2012 9:11:42

Grantek Systems’ Golden Batch Tool

• Let’s walk through the steps of setting up a Golden Batch

• Choose the recipe

Copyright © 2011 Rockwell Automation, Inc. All rights reserved.

• Select Batches from Historian• By Batch ID• By Date

• Highlight Batches for Comparison

Page 23: Maximizing Process Efficiency Using Golden Batch Analysis · Title: Microsoft PowerPoint - CS17_Grantek_FINAL [Compatibility Mode] Author: tcrichar Created Date: 1/5/2012 9:11:42

Grantek Systems’ Golden Batch Tool

• Let’s walk through the steps of setting up a Golden Batch

• Choose the phases

Copyright © 2011 Rockwell Automation, Inc. All rights reserved.

Page 24: Maximizing Process Efficiency Using Golden Batch Analysis · Title: Microsoft PowerPoint - CS17_Grantek_FINAL [Compatibility Mode] Author: tcrichar Created Date: 1/5/2012 9:11:42

Grantek Systems’ Golden Batch Tool

• Let’s walk through the steps of setting up a Golden Batch

• Set up Statistics and trending

Copyright © 2011 Rockwell Automation, Inc. All rights reserved.

Page 25: Maximizing Process Efficiency Using Golden Batch Analysis · Title: Microsoft PowerPoint - CS17_Grantek_FINAL [Compatibility Mode] Author: tcrichar Created Date: 1/5/2012 9:11:42

Grantek Systems’ Golden Batch Tool

• Running a Batch.

Copyright © 2011 Rockwell Automation, Inc. All rights reserved.

Page 26: Maximizing Process Efficiency Using Golden Batch Analysis · Title: Microsoft PowerPoint - CS17_Grantek_FINAL [Compatibility Mode] Author: tcrichar Created Date: 1/5/2012 9:11:42

Grantek Systems’ Golden Batch Tool

• Let’s run a batch, and compare it to our Golden Batch

Copyright © 2011 Rockwell Automation, Inc. All rights reserved.

Page 27: Maximizing Process Efficiency Using Golden Batch Analysis · Title: Microsoft PowerPoint - CS17_Grantek_FINAL [Compatibility Mode] Author: tcrichar Created Date: 1/5/2012 9:11:42

Grantek Systems’ Golden Batch Tool

• Let’s run a batch, and compare it to our Golden Batch

• The Gantt Area in Detail

Copyright © 2011 Rockwell Automation, Inc. All rights reserved.

Page 28: Maximizing Process Efficiency Using Golden Batch Analysis · Title: Microsoft PowerPoint - CS17_Grantek_FINAL [Compatibility Mode] Author: tcrichar Created Date: 1/5/2012 9:11:42

Grantek Systems’ Golden Batch Tool

• Let’s run a batch, and compare it to our Golden Batch

• The Trending & Statistics Area in Detail:

Copyright © 2011 Rockwell Automation, Inc. All rights reserved.

Page 29: Maximizing Process Efficiency Using Golden Batch Analysis · Title: Microsoft PowerPoint - CS17_Grantek_FINAL [Compatibility Mode] Author: tcrichar Created Date: 1/5/2012 9:11:42

Grantek Systems’ Golden Batch Tool

• Let’s run a batch, and compare it to our Golden Batch

Copyright © 2011 Rockwell Automation, Inc. All rights reserved.

Page 30: Maximizing Process Efficiency Using Golden Batch Analysis · Title: Microsoft PowerPoint - CS17_Grantek_FINAL [Compatibility Mode] Author: tcrichar Created Date: 1/5/2012 9:11:42

Copyright © 2011 Rockwell Automation, Inc. All rights reserved.

Grantek Systems’ Golden Batch Tool

• Future

– Control limits based on Golden batch process data. UL, CL, LL based on X standard deviations.

– Notifications will be sent using the Notification Engine 4.1

Page 31: Maximizing Process Efficiency Using Golden Batch Analysis · Title: Microsoft PowerPoint - CS17_Grantek_FINAL [Compatibility Mode] Author: tcrichar Created Date: 1/5/2012 9:11:42

• Our goal is for users to be:

• Enabled you to build the Golden Batch from the best

performance your plant has done on individual phases

– Build Golden Batch

– Set UL, CL, LL based on 6 Sigma of historical data

• Enabled your operator with real time tracking of the

current batch performance against the Golden Batch.

– Knowing real time current process parameters vs. golden

– Prediction of where the parameter should be trending

– Reduced lost or reworked batches

– Improved quality

Copyright © 2011 Rockwell Automation, Inc. All rights reserved.

Grantek Systems’ Golden Batch Tool

Page 32: Maximizing Process Efficiency Using Golden Batch Analysis · Title: Microsoft PowerPoint - CS17_Grantek_FINAL [Compatibility Mode] Author: tcrichar Created Date: 1/5/2012 9:11:42

Questions

Copyright © 2011 Rockwell Automation, Inc. All rights reserved.

Michael Lohmeyer / Grantek Systems