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PI at. More than just dessert!. About Eastman…. Headquarters: Kingsport, TN Manufactures and Markets Plastics, Chemicals & Fibers About 15,000 employees 30 countries 2000 sales: $5.3 billion. Manufacturing Sites. Kallo, Belguim. Middelburg, Netherlands. Rotterdam, Netherlands - PowerPoint PPT Presentation
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PI at PI at
More than just dessert!
About Eastman…
Headquarters: Kingsport, TNManufactures and Markets
Plastics, Chemicals & Fibers
About 15,000 employees
30 countries
2000 sales: $5.3 billion.
ArgentinaArgentinaPETPET
Moundsville, ALMoundsville, AL
Philadelphia, PAPhiladelphia, PA
Uruapan, MexicoUruapan, Mexico
Rexdale, Ontario, CanadaRexdale, Ontario, Canada
Pleasant Prairie, WIPleasant Prairie, WI
Newark, NJNewark, NJ
LaVergne, TNLaVergne, TN
Columbus, GAColumbus, GA
Forest Park,, GAForest Park,, GA
Ennis, TXEnnis, TX
Lynwood, CALynwood, CA
Portland, ORPortland, OR
South Holland, ILSouth Holland, IL
Carpentersville, ILCarpentersville, IL
Toronto,Toronto,CanadaCanadaPETPET
Jefferson, PAJefferson, PA
Franklin, VAFranklin, VA
Columbia, SCColumbia, SCPETPET
Kingsport, TNKingsport, TNhundreds of chemicals,hundreds of chemicals,fibers & plasticsfibers & plastics
Batesville, ARBatesville, ARspecialty organicspecialty organicchemicalschemicals
Longview, TXLongview, TXover 40 chemicalsover 40 chemicals& plastics& plastics
Roebuck, SCRoebuck, SCtextile chemicalstextile chemicals
Savannah, GASavannah, GA
Veracruz, MexicoVeracruz, MexicoPETPET
Sokolov, Czech RepublicSokolov, Czech Republictextile chemicalstextile chemicals
Waterford,Waterford,IrelandIreland
Kallo, BelguimKallo, Belguim
Bury, UKBury, UK
Sant’ Albano, ItalySant’ Albano, Italy
Cola’ Di Lazise, ItalyCola’ Di Lazise, Italy
Molndal, SweedenMolndal, Sweeden
Middelburg, NetherlandsMiddelburg, Netherlands
Rotterdam, NetherlandsRotterdam, NetherlandsPTA & PETPTA & PET
Stonehouse, UKStonehouse, UK
Hamburg, GermanyHamburg, Germanyspecialty polymersspecialty polymers
Dusseldorf, Ger.Dusseldorf, Ger.specialty polymersspecialty polymers
WalesWalesfine chemicalsfine chemicals
SpainSpainPET & CHDMPET & CHDM
Kuantan, MalaysiaKuantan, MalaysiaEastar & SpectarEastar & Spectar
Jurong Town, SingaporeJurong Town, Singapore
Nan Ping, ChinaNan Ping, China
Tanggu, ChinaTanggu, China
Hong KongHong Kongpharmaceuticalpharmaceuticalintermediatesintermediates
SingaporeSingaporeOXO chemicalsOXO chemicals
Nanjing, ChinaNanjing, ChinaeasTotac hydrocarboneasTotac hydrocarbontackifying resintackifying resin(to be completed late (to be completed late 2000)2000)
WorkingtonWorkington
HartlepoolHartlepool
Manufacturing Sites
Presenters
Johnette McDanielPrincipal Systems AnalystLongview, TexasLeader - PS-RLINK Worldwide
Bill WightSystems AssociateKingsport, TennesseeProject ArchitectProcess Excellence Team
History of PI at Eastman
‘90- 40,000 tags - Utilities Control System‘93- Manufacturing Process Improvement
- Utilities Expands Functionality‘94- Manufacturing Links to AI Tools (EPC)
- Interface PI to Internal MES’s‘95- Full Information System (Different Archive)‘97- Began MESA Project (1.6M tags)‘99- Two Latin American Plants in Operation‘01- North American Startup
Manufacturing Enterprise Systems Alignment
What’s a “ ”?What’s a “ ”?
Manufacturing Enterprise Systems Alignment
ArchitectureArchitecture
ProductArchitecture
Common User View
R/3
Planning
Schedule
Initiate Production
Runs
Production Records
Inventory Management
Ship
EIW
Process/ Product
Knowledge
Mgmt. Summary
Bus. Intel.
Decision Support
PIMS
Process Control
Process Conditions
Lab Inst.
LIMS
Functional Architecture
Process Data Collection
Data ArchivingTrend DisplaysExcel InterfacePerf.
Equations
Mgmt. Reporting
Oper. Reporting
Measures“Roll-up”MIS Data
Feeds
Sample Mgmt.Instrument
InterfacingSPC Data FeedCalibrationStandardsMethods
Inventory TrackingPlanning/
SchedulingBatch RecordsQuality Release
Process RecipesProcess
InstructionsCert. Of AnalysisShipping
SPCStd. DisplaysLab Data
AccessCalc.
ProductionCalc. Usage
ProcessProcess
DataData
SAP R/3
TrackTrack
MaterialsMaterials Purchased LIMS
Scales, PCS
Physical Architecture - I
PIMS
Materials (R/3)
RecordRecord
AnalysesAnalyses
ApplyApply
StatisticsStatistics
DataData
AnalysisAnalysis
Information
Physical Architecture - II
RS/6000AIX
Oracle
RS/6000AIX
Oracle
DELLNT ServerSQLServer
DELLNT ServerSQLServer
TCP/IPPS-RLINK
SM-IDI
TCP/IPPS-RLINK
SM-IDI
PI Products
•Archive
•Field Device Interfaces
•ProcessBook
•DataLink
•AlarmView
•Manual Logger (incl. HHT)
•BatchView
•SQC add-in
Team “Products”
• Process Changes
•Datasheets
•SampleMonitor
•SPC Alarm Client
•Required Data Monitor
• LIMS Interface
•Statistical Analysis Facility
Manufacturing Manufacturing Business ProcessesBusiness Processes
• Receive Raw Materials
• Prepare to Produce Monitor Manufacturing
• Qualify Product
• Post Production / Usage
• Management Information
Monitor Manufacturing
PreparePrepare
Process Changes UtilityProcess Changes Utility
To LIMS:• Product ID• Batch No.• Process State
To LIMS:• Product ID• Batch No.• Process State
To PI:• State Tags• SPC Limits• Other Tag Settings
To PI:• State Tags• SPC Limits• Other Tag Settings
Monitor ManufacturingMonitor Manufacturing
Establish Process Conditions
Collect & CompareCollect & Compare
Data from multiple Instruments (Honeywell DCS, Fisher DCS, Fisher DeltaV DCS, Intellution Fix PC control)
OFF GAS PRESS RBL 30 STM DA-404 KLB/HR Blr12 Boiler Feed Water FlD-350 Bin Weight
1/6/00 7:54:33 AM 1/6/00 3:54:33 PM8.00 Hour(s)
54ADC:PI04B-57.PV
74DC:FC8E7.OP
52PI:FI-08-191/AI1.PV
WI350.PV
50
100
150
200
0
24077.03906
59.8
164.512
0.12
54ADC:PI04B-57.PV
74DC:FC8E7.OP
52PI:FI-08-191/AI1.PV
WI350.PV
Monitor ManufacturingMonitor Manufacturing
Data About the Health of the Process
To Expected Results
Archive, Trends, HHT, Analyticals
Archive, Trends, HHT, Analyticals
SampleMonitorSampleMonitor
DataSheetsDataSheets
SQC Add-inSQC Add-in
Alert & RespondAlert & RespondOperator to Deviations
Capture ResponseFor Later Analysis
Monitor ManufacturingMonitor Manufacturing
PIAlarmViewPIAlarmView
MESA Alarm ClientMESA Alarm Client
Select and RecordCauses & Actions
Select and RecordCauses & Actions
Manufacturing Manufacturing Business ProcessesBusiness Processes
• Receive Raw Materials
• Prepare to Produce
• Monitor Manufacturing
• Qualify Product Post Production / Usage
• Management Information
Post Production / Usage
Standard FeaturesStandard Features
• Start/Stop Control Recipes & Phases
• Processbook
•Automated via Excel
• Post actual Production, Consumption & Activity quantities
•Backflush Consumption Quantities (Unrestricted and Restricted)
•Varying Levels of Automation
PI-PCS Interface
User selectsUser selects
Default current time.
(User can change)
Default current time.
(User can change)
Calculated from LBS
Calculated from LBS
Calculated from flow rate PI tag.
User can change.
Calculated from flow rate PI tag.
User can change.
User selectsUser selects
Default from PI tags.
Default from PI tags.
DefaultDefault
Default from PI tags.
Default from PI tags.
Post Post Production
Unsolicited MessagesUnsolicited Messages
•Material Transfers
•Batch Creation (PI_BT_CR)
•Batch Characteristics
(PI_BT_CL)
PI to SAP
CustomizationsCustomizations
•SAP to PI-Tag Value Updates• Quality Test Results from SAP to PI
• System Management and Alarming
•Eastman Wrappers• Recipe Management
• Post Production/Usage/Activities
•Automated Tools
Bulk ConfigurationBulk Configuration
Digital TagsDigital Tags
PS-RLINK TagsPS-RLINK Tags
TestingTesting
Configure Configure Automated Configuration Tools
ManageManageAutomated User Tools
Control Recipe Stop/StartControl Recipe Stop/Start
ConfirmationConfirmation
Materials Maintenance
Materials Maintenance
Monitor Monitor Interface Monitoring
& Intervention
I/T Support AlarmsI/T Support Alarms
User AlarmsUser Alarms
Debugging ToolsDebugging Tools
PS-RLINK Statistics
•6 Manufacturing Divisions
•89 Resources (Reporting Locations)
•>800 Materials
•>12,000 MT Reported Daily
•Minimal Problems
Of course, there’s still…Of course, there’s still…
Manufacturing Manufacturing Business ProcessesBusiness Processes
• Receive Raw Materials
• Prepare to Produce
• Monitor Manufacturing
• Qualify Product
• Post Production / Usage Management
Information
Tools for Power Users
PI DataLink:Ad Hoc Query / End-User Dev.
PI DataLink:Ad Hoc Query / End-User Dev.
Stat. Analysis Facility:Quality System
MaintenanceChart Delivery
Stat. Analysis Facility:Quality System
MaintenanceChart Delivery
ProcessBook:Process Data vs.Analytical Data
ProcessBook:Process Data vs.Analytical Data
Required Data Monitor…ensuring that critical data is archived
ConfigureConfigure
MonitorMonitor
Cognos PowerPlay & Impromptu
ArgentinaArgentinaPETPET
Moundsville, ALMoundsville, AL
Philadelphia, PAPhiladelphia, PA
Uruapan, MexicoUruapan, Mexico
Rexdale, Ontario, CanadaRexdale, Ontario, Canada
Pleasant Prairie, WIPleasant Prairie, WI
Newark, NJNewark, NJ
LaVergne, TNLaVergne, TN
Columbus, GAColumbus, GA
Forest Park,, GAForest Park,, GA
Ennis, TXEnnis, TX
Lynwood, CALynwood, CA
Portland, ORPortland, OR
South Holland, ILSouth Holland, IL
Carpentersville, ILCarpentersville, IL
Toronto,Toronto,CanadaCanadaPETPET
Jefferson, PAJefferson, PA
Franklin, VAFranklin, VA
Columbia, SCColumbia, SCPETPET
Kingsport, TNKingsport, TNhundreds of chemicals,hundreds of chemicals,fibers & plasticsfibers & plastics
Batesville, ARBatesville, ARspecialty organicspecialty organicchemicalschemicals
Longview, TXLongview, TXover 40 chemicalsover 40 chemicals& plastics& plastics
Roebuck, SCRoebuck, SCtextile chemicalstextile chemicals
Savannah, GASavannah, GA
Veracruz, MexicoVeracruz, MexicoPETPET
Sokolov, Czech RepublicSokolov, Czech Republictextile chemicalstextile chemicals
Waterford,Waterford,IrelandIreland
Kallo, BelguimKallo, Belguim
Bury, UKBury, UK
Sant’ Albano, ItalySant’ Albano, Italy
Cola’ Di Lazise, ItalyCola’ Di Lazise, Italy
Molndal, SweedenMolndal, Sweeden
Middelburg, NetherlandsMiddelburg, Netherlands
Rotterdam, NetherlandsRotterdam, NetherlandsPTA & PETPTA & PET
Stonehouse, UKStonehouse, UK
Hamburg, GermanyHamburg, Germanyspecialty polymersspecialty polymers
Dusseldorf, Ger.Dusseldorf, Ger.specialty polymersspecialty polymers
WalesWalesfine chemicalsfine chemicals
SpainSpainPET & CHDMPET & CHDM
Kuantan, MalaysiaKuantan, MalaysiaEastar & SpectarEastar & Spectar
Jurong Town, SingaporeJurong Town, Singapore
Nan Ping, ChinaNan Ping, China
Tanggu, ChinaTanggu, China
Hong KongHong Kongpharmaceuticalpharmaceuticalintermediatesintermediates
SingaporeSingaporeOXO chemicalsOXO chemicals
Nanjing, ChinaNanjing, ChinaeasTotac hydrocarboneasTotac hydrocarbontackifying resintackifying resin(to be completed late (to be completed late 2000)2000)
WorkingtonWorkington
HartlepoolHartlepool
Manufacturing Sites
Questions?Questions?