smart operations: sustaining optimization through a connected enterprise
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2015 Honeywell Users Group
Europe, Middle East and Africa
Smart Operations: Sustaining Optimization through a
Connected Enterprise
Yiannis Bessiris, Honeywell
2 © 2015 Honeywell International All Rights Reserved
Outline
• Transformative time in the Industry and Challenges
• Smart Operations: Technology Enabling Business
Transformation
• Value Delivered
• Engagement Approach
3 © 2015 Honeywell International All Rights Reserved
Industrie 4.0
Are We Ready?!
Transformative Time
Cloud
Big Data Predictive Analytics
Connectivity
Industrial Internet of Things
Mobility
Gartner’s 2013 Predictions
“Key business transformation drivers”
4 © 2015 Honeywell International All Rights Reserved
HPI | An Industry in Change
Data Has No Value … Until You can Translate it into Action to Become Agile
It is estimated that 40 exabytes (4.0 x 1019) of
unique new information
will be generated worldwide this year
Shell …”Over 40 Pbyte (1015 or quadrillion) of data
today but growing by several factors in coming years”
5 © 2015 Honeywell International All Rights Reserved
Challenges: Need for a Paradigm Shift
…Leading to
*Global Energy Talent, 2015
** PWC, 2014
The need to transforming
how things are done to
remain competitive, taking
advantage of:
Customer Challenges…
average age of production engineers in
North America, leading to a 38%
forecasted shortage in talent by end of
decade*
Workforce
Expertise 51
More with
Less 40%
estimated OPEX reduction (vs. ‘14)
needed within fields in the North Sea to
remain vital at current oil prices**
Data
Overload/
Accessibility
22% of average annual revenue was lost
due to not being able to leverage
information collected***
Market
Pressure 40%
percent of process upsets caused by
human error. Increased competition &
more frequent market volatility is
making uptime even more critical****
• Business process
management and redesign
• Industrial Internet of Things
• Technology enablers:
Cloud, Mobility, Analytics
• Operational consolidation
• Reduced Lifecycle cost of
technology deployment
• Performance contracting
***Oracle “From Overload to Impact: An Industry Scorecard,” 2015
****ARC “Improving Margins with Smart Operations,”2015
6 © 2015 Honeywell International All Rights Reserved
Digital Transformation
Powered by Mobility, Cloud and OPC UA
1. Connectivity
Easier integration leading to pervasive analytics
2. Real-time
Now and always up to date information
3. Collaboration
Work process transformation. Knowledge retention
OPC UA Connectivity
Digital Transformation
Alarm & Operations
Management Solutions
Profit Solutions
Simulation & Competency
Solutions
Product Management,
Planning & Scheduling Solutions
Data, Analytics &
Collaboration Solutions
Industry Vertical
Solutions
Cloud
Mobility
7 © 2015 Honeywell International All Rights Reserved
Suite of Honeywell Advanced Solutions
For Improved Safety, Reliability, Efficiency and Sustainability
Digital Transformation
Alarm & Operations
Management Solutions
Profit Solutions
Simulation & Competency
Solutions
Product Management,
Planning & Scheduling Solutions
Data, Analytics &
Collaboration Solutions
Industry Vertical
Solutions
• Advanced Process Control • Blending & Movement Management
• Process Design • Operator Competency • Corrosion
• Production Management • Advanced Planning & Scheduling
• Enterprise Collaboration • Uniformance (PHA) • Uniformance Sentinel • Sentinel Mine
• Digital Suites for Oil & Gas • OptiVision
• Dynamo Alarm Management • Dynamo Operations Management
8 © 2015 Honeywell International All Rights Reserved
Suite of Honeywell Advanced Solutions
For Improved Safety, Reliability, Efficiency and Sustainability
Digital Transformation
Alarm & Operations
Management Solutions
Profit Solutions
Simulation & Competency
Solutions
Product Management,
Planning & Scheduling Solutions
Data, Analytics &
Collaboration Solutions
Industry Vertical
Solutions
• Advanced Process Control • Blending & Movement Management
• Process Design • Operator Competency • Corrosion
• Production Management • Advanced Planning & Scheduling
• Enterprise Collaboration • Uniformance (PHA) • Uniformance Sentinel • Sentinel Mine
• Digital Suites for Oil & Gas • OptiVision
• Dynamo Alarm Management • Dynamo Operations Management
9 © 2015 Honeywell International All Rights Reserved
DynAMo® Alarm & Operations Management
Improved Plant Safety, Availability & Compliance across Enterprise
Alarm Management
Stale and Standing Alarm
Safety Bypasses and Inhibits
Critical Alarm Limits
Boundaries and Constraints
Operations Logbook
Secure Shift Handover Process
Shift Log History Compliance
Critical Alarm Limit Recording
Operations Monitoring
Critical Limit Deviations
Excursions from Production
Envelopes
Integrity Operating Windows
Next generation integrated Suite goes beyond the Operator and
enables new workflows to better manage Operations integrity
10 © 2015 Honeywell International All Rights Reserved
DynAMo® Alarm & Operations Management
Improved Plant Safety, Availability & Compliance across Enterprise
Alarm Management
Stale and Standing Alarm
Safety Bypasses and Inhibits
Critical Alarm Limits
Boundaries and Constraints
Operations Logbook
Secure Shift Handover Process
Shift Log History Compliance
Critical Alarm Limit Recording
Operations Monitoring
Critical Limit Deviations
Excursions from Production
Envelopes
Integrity Operating Windows
`
Business
Layer
Process
Automation/
Operations
Plant
Management/
Maintenance
Operator
Next generation integrated Suite goes beyond the Operator and
enables new workflows to better manage Operations integrity
11 © 2015 Honeywell International All Rights Reserved
DynAMo® Mobility
One Single, Vendor-Neutral, Mobile Enabled Solution
Situational Awareness and Collaboration
Honeywell “Pulse”
12 © 2015 Honeywell International All Rights Reserved
Suite of Honeywell Advanced Solutions
For Improved Safety, Reliability, Efficiency and Sustainability
Digital Transformation
Alarm & Operations
Management Solutions
Profit Solutions
Simulation & Competency
Solutions
Product Management,
Planning & Scheduling Solutions
Data, Analytics &
Collaboration Solutions
Industry Vertical
Solutions
• Advanced Process Control • Blending & Movement Management
• Process Design • Operator Competency • Corrosion
• Production Management • Advanced Planning & Scheduling
• Enterprise Collaboration • Uniformance (PHA) • Uniformance Sentinel • Sentinel Mine
• Digital Suites for Oil & Gas • OptiVision
• Dynamo Alarm Management • Dynamo Operations Management
13 © 2015 Honeywell International All Rights Reserved
Uniformance Asset Sentinel
Real-time Performance Monitoring: Asset Surveillance
Asset Sentinel
14 © 2015 Honeywell International All Rights Reserved
Uniformance KPI Management
Right Decisions Faster, Transforms Work Practices, Drives Collaboration
Process monitoring results rolled-up
and combined with other business KPI’s
• Role-based KPIs
supporting different
functional key areas of
data (like HSE, financial,
product, reliability, ...)
for each role
• Drill down dashboards
to share root causes
• Real-time monitoring
• Use SharePoint’s
collaboration and work
flow
15 © 2015 Honeywell International All Rights Reserved
Suite of Honeywell Advanced Solutions
For Improved Safety, Reliability, Efficiency and Sustainability
Digital Transformation
Alarm & Operations
Management Solutions
Profit Solutions
Simulation & Competency
Solutions
Product Management,
Planning & Scheduling Solutions
Data, Analytics &
Collaboration Solutions
Industry Vertical
Solutions
• Advanced Process Control • Blending & Movement Management
• Process Design • Operator Competency • Corrosion
• Production Management • Advanced Planning & Scheduling
• Enterprise Collaboration • Uniformance (PHA) • Uniformance Sentinel • Sentinel Mine
• Digital Suites for Oil & Gas • OptiVision
• Dynamo Alarm Management • Dynamo Operations Management
Digital Transformation
Intuition ® Executive (IX)
16 © 2015 Honeywell International All Rights Reserved
Intuition® Executive (IX)
IX Closes the Loop & Enables Smart Operations
Continuous
Improvement
Converts your
business and process
data to key metrics
Provides visualization,
analysis and enables
collaboration
Monitors progress and
captures improvements,
knowledge
Workflows to ensure
appropriate actions are
implemented
Collaboration
Work Flow
Metric Management
Data/ Actions
17 © 2015 Honeywell International All Rights Reserved
Intuition® Executive Architecture
IX Closes the Loop & Enables Smart Operations
Intuition
Solutions
Components
Intuition Core
Data Access
Services Calculations
Reporting Notification
Workflow
Model
Management
Intuition Executive
Mobile
Framework
Visual
Controls
Event
Management
Event
Archive
Un
ifo
rma
nc
e
KP
I
Ma
na
ge
me
nt
Dyn
AM
o
Ala
rm
Ma
na
ge
me
nt
Dyn
AM
o
Op
era
tio
ns
Mo
nit
ori
ng
Intuition Applications
… F
utu
re
De
ve
lop
me
nt
Ap
plic
ati
on
1
3rd Party
Ap
plic
ati
on
2
Un
ifo
rma
nc
e
As
se
t S
en
tin
el
Dyn
AM
O
Mo
bilit
y
18 © 2015 Honeywell International All Rights Reserved
Operating Assets
Data Integration
Analytics
Reporting / Dashboards
Enterprise
Decision Support System
Evaluate Opportunities
Prioritize / Execute
Data Knowledge Action
Work Process Transformation
Aligning Business Objectives to Operational decisions
Bringing ‘Smart’ to the Operations
19 © 2015 Honeywell International All Rights Reserved
Solutions to Drive Real Value
Connecting the Enterprise to drive Smart Decisions
Incremental Value Challenges
2-5% increase in Operating
Margin
Market
Pressure
Operational Agility
Faster responses to market conditions
5-15% Reduction in OPEX
More with
Less
Operational Excellence
Lower production costs/ Improved OPEX Efficiency
Workforce
Expertise
Competency Management / Collaboration
Knowledge Retention
Improving Situational Awareness
Data
Overload/
Accessibility
Real time Exception Based Surveillance
Improved Safety and Business Performance
10-15% Reduction in unplanned production deferments
Smart Ops Solutions
30-50% reduction in
start-ups
Higher productive
workforce:
$350K/Operator (API study)
20 © 2015 Honeywell International All Rights Reserved
Smart Operations Deployment
Enterprise Deployment of Key Initiatives
Asset Utilization
Condition Based Monitoring
Operations Excellence
Competency Management
Real Time Production Monitoring
Energy Management
Translates into Faster Deployment and Higher ROI
21 © 2015 Honeywell International All Rights Reserved
Manufacturing Information Intelligence System (MIIS)
Enterprise Connectivity Collaboration Real Time Analytics
• Integration and visibility across functions
• Enable near real time performance monitoring
• Standardization of KPI definitions
• Fact based decision support system
• Collaborative Environment monitors and drives
accountability
Reliance Industries Ltd
MIIS Transformation Objectives
22 © 2015 Honeywell International All Rights Reserved
Business Transformation Priorities
In keeping with the requirement of time, Reliance has identified areas where
“transformation” is a necessity.
“Transformation” areas include:
• HSEF
• Operations
• Reliability Engineering and
Maintenance (REAM)
• Technology
• Automation
• Energy
• People
• Values
• Reliance and Honeywell are partnering towards Operational Excellence through automation by adopting best practices tailor made to fit the purpose.
• A significant improvement towards the objective has started to surface
23 © 2015 Honeywell International All Rights Reserved
Reliance Industries Ltd.
Manufacturing Information Intelligence System (MIIS) Initiative
Operations
Management
Operator
Competency
Performance
Management
• Operations Monitoring and
Limits management
• Operator logbook for effective
shift handover
• Develop, implement & maintain
High Fidelity Operator Training
Simulator for every plant, at all
sites
• Information integration
• Role-based KPIs and
Dashboards
• Real-time Monitoring and
Collaboration
• Maintaining Operational
Integrity (Safety)
• Standard work processes
• Improved situational
awareness & communication
• Enhance Operator
Competency
• Increase productivity
• Improved operational
consistency
• Energy savings
• Visibility and Agility
24 © 2015 Honeywell International All Rights Reserved
Reliance Industries Ltd.
Great Example of A Connected Enterprise
Enterprise Performance Management – Real Time KPIs for 2000+ Users (Role-based)
– Connecting 80+ base systems and 14 sites
– 18 Functional Areas
Drill down dashboards
Transforms work practices
Converts data into knowledge
Drives collaboration
Note: Above screenshot is from
Honeywell’s demo system
25 © 2015 Honeywell International All Rights Reserved
Reliance Industries Ltd.
Rich Drill-downs To Get To Metrics And To Decisions Faster
26 © 2015 Honeywell International All Rights Reserved
Knowledge Capture: Collaborate with Experts
• Tools for the end-user to
collaborate with other
peers and experts
• Capture the knowledge of
your experts with
collaborative tools ‒ Training junior staff or for
when experts are
unavailable
• Improve personnel
productivity ‒ Searchable information in
document libraries, wikis
27 © 2015 Honeywell International All Rights Reserved
Collaboration to drive Actions: Closing the Loop
• Ensuring missed targets,
operational gaps to Actions
• Morning meetings
• Refinery manager meetings
28 © 2015 Honeywell International All Rights Reserved
Shell Deepwater Production Surveillance
Connected Assets and Analytics driving Smart Operations
New Orleans Based Surveillance Center for Deep Water Assets in the Gulf of Mexico and off the Coast of Brazil – ~300 Wells across 11 Floating Structures & 2 FPSOs
– 23M Data points processed per day
– 180K daily executed anomaly detections
Benefits – Improved Reliability and Safety
– Prevent Production Deferment
– Prevent Equipment Failure
– People Enablement - Increased Work Efficiency
30 © 2015 Honeywell International All Rights Reserved
Eliminate Waste, Increase Efficiency,
Focus on High Value activities
Connected Assets and Analytics driving Smart Operations
31 © 2015 Honeywell International All Rights Reserved
Surveillance Business Process – An example
Connected Assets and Analytics driving Smart Operations
32 © 2015 Honeywell International All Rights Reserved
Identify, quantify
(ROI) specific
opportunities
Develop a ROI
Based
Deployment
Road-map
Develop solution
maps, KPI driven
execution plan,
organization
teams for
deployment.
Review/update
business
processes (BPM)
Develop a
delivery model
Deployment of
technology with
transformed
work processes
Facilitate Change
management
Program
management to
monitor
progress, track
benefits
Develop a
Support model
(remote, site
visits) to assist
in ensuring
continued
business results
Scheduled
audits/reviews of
KPI
Phase 1 Vision & Concept
Phase 2 Discovery
Process
Opportunity
Assessment
Phase 3 Front End
Engineering
(FEED)
Phase 4 Project
Execution
Phase 5 Life Cycle
Management
(A360)
Validate
business
objectives
Developing a
business case
with
Benchmarking,
Workshops
How We Deliver
Consultative Scalable Approach
33 © 2015 Honeywell International All Rights Reserved
PHASE 1 Example - Vision / Concept
• Identification and Validation of Business Drivers
• Establishing a Base line on Expected Value
• Alignment of Business Drivers to Operational Objectives
34 © 2015 Honeywell International All Rights Reserved
Engagement Approach
Example - Opportunity Assessment
• Workshops to Engage with the key stakeholders
from different functional groups within an organization
• Definition of Opportunities
35 © 2015 Honeywell International All Rights Reserved
Occupational S
afe
ty
Pro
cess S
afe
tyR
egula
tory
Com
plia
nce
Opera
tional E
ffectiveness
Info
rmation M
anagem
ent
Opera
tions M
anagem
ent
Advanced A
larm
Managem
ent
Asset M
anagem
ent
Opera
tors
Tra
inin
g S
imula
tors
AP
C (
Early E
vent D
ete
ction)
Inte
llatr
ac
One W
irele
ss
Pro
cedura
l O
pera
tions
Ala
rm P
erf
orm
ance A
ssessm
ent
Ala
rm P
hilo
sophy W
ork
shop
Ala
rm R
ationaliz
ation S
erv
ice
Boundary
Assessm
ent
Benchm
ark
ing / G
ap A
naly
sis
Pro
cedura
l C
onsultin
g
Benefit A
naly
sis
(site A
dult)
Valu
e A
udit
Business Drivers Solution Layout Consulting Services LayoutCustomer Opportunities
X Accident Avoidance X X X X X X X
X X Downtime Avoidance X X X X
X X Loss Prevention X X X X X X X
X X Asset Reliability X X X X X
X Boundary Management X X X
X Emission Compliance X X X X
X Procedural Management X X X X X X
X X Operators Training X X X
X Simulation (Training & validation) X
X X X Alarm Rationalization X X X X X
X Alarm Performance Management X X X X X
X X X X X Early Process upset Identification X X X X X
X Increase Process Repeatability X X X
X Operators data errors X X X
X X X X X Improve Emergency Response X X X X X X X X
X X X Auditability X X X
X Safe Profitability X X X X X X X X X
X Abnormal Situation Management X X X X X X
Business Drivers Solution Layout Consulting Services Layout
PHASE 2 Example – Discovery Process
36 © 2015 Honeywell International All Rights Reserved
Output of our Consulting Study – a Strategic &Tactical Roadmap
Real Time
Reporting
And
Visualization
KPI
Dashboards
Integration
Analytics
Critical Equipment
Monitoring
Proactive
Surveillance
System
Site Level Deployment Enterprise Deployment
Business
System
Integration
Operations
Monitoring
System
ROC setup
Uniformance Insight
iForms
Uniformance KPI
IX
Uniformance Sentinel
Uniformance Sentinel
Integration with KPI
IOM
IOL
Mobility applications
ERP integration
CMMS integration
Collaboration station
Cybersecurity
PHASE 2 Example – ROI based deployment
Year 1 Year 2 Year 3 Year 4
38 © 2015 Honeywell International All Rights Reserved
Phase 3 Example – FEED & BPM
Solution Mapping
Work process Maps
ROI Driven Execution Plan
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