production visibility: kpi’s in real-time basf – the chemical company sharon brown wonderware...

Production visibility: KPI’s in Real-timeBASF – The Chemical Company

Sharon BrownWonderware S.A.

Introduction

BASF - The Chemical Company

“We were able to reduce scrap, downtime and smoothed change-overs by the increase in total visibility of our production process”

Agenda

Introduction

Project Solution

Benefits

Considerations

Summary

BASF – Chemical Company

► International Company▪ Diversified foot print around the world

► Chemicals are it main business▪ In South Africa, it includes plastics, polyurethanes,

agricultural, leather, chemical and automotive sectors.

► BASF Port Elizabeth Catalytic converter industry One of the highest users of precious metals for the

automotive sector Roughly 39% market share, which represents

roughly 5.5 million parts in 2008.

Process Background

PRODUCTION AREA

SLURRY AREA

COATING LINES

MIXING AREA LABORATORY / QA

► Slurry Manufacturing▪ Mixing▪ Customer / Part Specific

► Mixing ▪ Slurry are mixed

► Q/A▪ Quality checks▪ Manage waste

► Production▪ Coating lines▪ Various machines – client

chosen technology

Agenda

Introduction

Project Solution

Benefits

Considerations

Summary

Topology - Before new installation

Network TCP/IP (LAN)

MIXING AREA

PRODUCTION AREA

SLURRY AREA

LAB / QA

InTouch SCADA

InTouch SCADA

LIMS – ORACLE DB

InTouch SCADA

MS SQL Server

InTouch22 Stations

Appr. 50 000 I/O

25 K Historian10 A/F Clients

Siemens (S7) onEthernet

Key Requirements

► No real-time visibility of the process.▪ Equipment Status▪ Process Status▪ Maintenance Status

► Lack of communication between production and maintenance staff due to lack of information.

► No access to key performance indicators▪ Production variables▪ Production Rate / Figures

Key Requirements

► More central monitoring of production flow▪ The information was only available at SCADA

level at the machine

► Required access to production reports by management

Project Goals - Technical

► Install a central repository of real-time data that links the current SCADA’s, production databases and LIMS data.

► Capitalize on already available infrastructure of Wonderware SCADA and Historian

► Make the operation more visually representative to all involved using a Web interface

Project Goals - Business

► Due to the nature of the business, the raw material are of extreme high value▪ i.e. precious metals – platinum

► Main goal is to keep scrap levels as low as possible and minimize rework and production cost.

► How?

How to realize these Goals

► Need to reduce downtime► Anticipate production problems ► Departments to take joint responsibility

for critical dependencies► Reduce change-over times► Improve overall coating rate

Why Wonderware

► Existing Wonderware install base.▪ InTouch SCADA network of appr. 50 000 I/O▪ Wonderware Historian 2K5 and Active Factory

clients

► BASF wanted to utilise their present investment

► Scalability of the Wonderware solution

Why Wonderware

► Information Server from Wonderware (WIS) provided a solution

► Good working relationship has been built up with the supplier

► Top quality training is provided

Project Solution

► Solution aimed at making the information more centrally accessible

• Control Room environment• Web Clients for managers

► Displaying the coating, slurry and operation information

• Production Data• Downtime• Machine and process Status

Implementation - Prerequisites

► First step Involve production and maintenance resources to determine the information needed

► Made each person Responsible for the availability of the data by ▪ Training▪ Do own modifications on the SCADA

Taking ownership of the system

How it was implemented

► Installed the Wonderware Information Server (WIS)

► Gather data from various systems in the plant ▪ Both Wonderware and other sources.

► Control room set up with multiple large LCD displays▪ Both production and maintenance used.

► Build web based reports for management ► Project took 3 months

Data acquired – Multiple Sources

ACTIVE FACTORY /WE CLIENTS

CONTROL ROOM

Historian / Information Server

SCADA Systems

InTouch

COATING LINES

MS SQL Server 2005

SLURRY MANUFACTURING

MS SQL Server 2005

LIMS

Oracle DB

Topology

Plant PLC’s

Network TCP/IP (LAN)

Plant PLC’s

MIXING AREA

PRODUCTION AREA

SLURRY AREA

LAB / QA

InTouch SCADA

InTouch SCADA

LIMS – ORACLE DB

Plant PLC’s

InTouch SCADA

MS SQL Server

CONTROL ROOM

Wonderware HistorianMS SQL ServerWeb Portal – Information Server

WIS Clients

Active Factory Clients

► Wonderware Information Server (WIS) Clients

Multi Views

Control Room

Real-time Graphics InTouch

KPI’sDowntime StatusAlarm Conditions

Trends and Charts Historian

Average rates of the coating.

Drill-down Reports Table Weaver

Collaborating Data from different sources

Agenda

Introduction

Project Solution

Benefits

Considerations

Summary

Benefits / Goals Achieved

Initial Goal Comment

Central Repository of real-time data

Control Room with real-time data display from various system

Capitalize on existing Wonderware installation

No additional cost for software was incurred

Provide value to all plant sections to improve production/maintenance

Factory sections took ownership – previously under utilized SCADA network has become a crucial resource and tool.

Reduce downtime, scrap levels and as a result production cost

Reduction of 2,5 hours downtime per week as a result less scrap and an increase in production

Improve Average Coating Rate

Coating rates have improved – no percentage improvement available yet due to changes in processes. Busy analyzing new average rates.

Agenda

Introduction

Project Solution

Benefits

Considerations

Summary

Considerations

► Infrastructure (PLC network and LAN) was in place which made it easier to gather the data

► We started by doing training first

► Involving maintenance, production and process engineering made the project run smoother

Agenda

Introduction

Project Solution

Benefits

Considerations

Summary

In Conclusion

Richard Mangold Service Platform Manager

“ The Wonderware package is very broad, the more training and awareness, the more it can be utilized becomes a true asset to the company.”“Attend more sessions, breakfasts and road

shows – the benefits are there!”

Questions

Thank you for attending