mit mes optimierungspotentiale in der prozessindustrie...

Mit MES Optimierungspotentiale in

der Prozessindustrie erschliessen

Hisham K. Mubarak

1 11.04.2013 5. MES-TagungHannover Messe 2013

2

BASF SE at a glance

MES as Key for Operational Excellence

Best Practice MES in Process Industry

Summary & Outlook

5. MES-TagungHannover Messe 2013 11.04.2013

BASF – The Chemical Company Around 400 production sites with around 800 production plants

Our chemicals are used in almost all

industries

We combine economic success, social

responsibility and environmental

protection

Sales 2012: €78,729 million

EBIT 2012: €8,976 million

Employees (as of December 31, 2012):

113,262

In 2012, BASF filed for around 1,170 new

patents worldwide

6 Verbund sites and around 380

production sites

3

Platzhalter für Bild


BASF worldwide

Sites

4

Regional centers

Selected

production sites

Verbund sites

Most important

research sites

Freeport Geismar

São Paulo

Ludwigshafen Antwerp

Hong Kong

Kuantan Singapore

Nanjing

Florham Park


Verbund site Ludwigshafen

Headquarter

Employees BASF SE 34,769 *

Site area 10 km²

Sales products about 8.5 million metric tons p.a.

Road 106 km

Rail 230 km

Site traffic 2,100 trucks daily

Shipment 100,000 containers p.a.

Pipeline system about 2,800 km

Production facilities circa 160 production plants

The largest integrated chemical complex

in the world

11.04.2013 5 5. MES-TagungHannover Messe 2013

6

BASF SE at a glance


Best Practices MES in Process Industry

Summary & Outlook


“Do things right!”

OpEx is BASF’s target state of

superior performance in chemistry

OpEx is achieved when operations are transparent, stabilized, optimized, learning, adaptive and have reached the maximum fit with business strategy.

We strive for OpEx in order to increase business success by profitable growth from operations.

To achieve OpEx, we drive a process to continuously challenge and improve the performance of operations.

Achieving Operational Excellence (OpEx)

is a Continuous Challenge for Plant

Operators

5. MES-TagungHannover Messe 2013 7 11.04.2013

MESs are key to create transparency, to analyze opportunities and to move towards Operational Excellence

Time

Mat

uri

ty

Operations are transparent KPIs for improvement levers, visual mgmt, etc.

Operations are stabilized with respect to safety, quality, availability etc.

Operations are optimized

improved knowledge and balanced resources

Operations are learning

cont. improvement as basis for development

Operations are adaptive

maximum value creation through adaptability

Operations have reached maximum fit

with business strategy

5. MES-TagungHannover Messe 2013 8 11.04.2013

11.04.2013 5. MES-TagungHannover Messe 2013 9

Non-productive tasks reduce time available for process optimization

Need for complexity management

Process analysis

Analysis of optimization hypothesis

require manual data integration from several

systems (LIMS, PIMS, DCS alarms, SAP, ...)

Help !!

Digital Tsunami

Reality: Complexity is overwhelming process managers

MES Support Management and

Optimization of Operational Processes

Manufacturing Execution Systems are tools for automation and support of operational

processes in production, quality, logistics and maintenance.

MESs manage, monitor and synchronize the execution of real-time, physical processes

involved in transforming raw materials into intermediate and/or finished goods.

MESs applications provide feedback on process performance, and support component-

and material-level traceability, genealogy, and integration with process history.

MESs coordinate the execution of work orders with production scheduling and

enterprise-level systems.

10

What is a MES?

Process data analysis

Documentation and archieving of production process data

Analysis of plant status and operation modes

Monitoring of production KPIs

Information integration of systems From Data to Information!


Manufacturing Execution Systems Need

to be Tailored for Each Plant

Raw material Warehouse and delivery production filling lab

Tank farm

control DCS

FPLS/

LIMS

warehouse

control Filling

Control PCS TCS TCS

Cost Calculation

Production planning Sales and Delivery

Reclamation Management

Operative Produktions- und

Instandhaltungsplanung

Reporting von Verbrauchen,

Produktionsmengen und Beständen

Bewertung der Prozess-

und Anlagenperformance

...

Effizienzsteigerung und

Prozessoptimierung

KPI-Monitoring

Condition Based

Maintenance

Process Data

Analysis

Detailed Scheduling

Batch Monitoring and

Analysis

Shift book and

report book

Information

Integration

Plant Asset

Management

Production

Documentation Quality Driven

Process Control

Operational

focus

Business

focus


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12

BASF SE at a glance



Summary & Outlook


13

Plant Information Management Systems (PIMS)

serve as standard data source for MES

applications

Trend View

(out of the box)

Batch Analysis SAP-Integration

Februar 2002

27.02.2002

Messstelle P_1170.X P_1811.HDAC

06:00 27.05.2002 15:48:23 27.05.2002 15:20:26

4,00390625 AUTOMATIKBAR

Druckreglung Druckregelung

Wertermittlung TagesAnfang Min Max Mittel Laufzeit

Vorgabe 3,8 4,5 AUTOMATIK

So 17.02.2002 4,517064571 4,13961935 5 4,710282326 24

Mo 18.02.2002 4,54659605 4,39453125 4,838867188 4,635050297 24

Di 19.02.2002 4,395897865 4,395897865 5 4,704075813 24

Mi 20.02.2002 4,359872341 4,345703125 4,477539063 4,436131954 24

Do 21.02.2002 4,51008606 4,359872341 4,819335938 4,554921627 24

Fr 22.02.2002 3,996413231 3,984375 4,697265625 4,425307274 21,42638889

Sa 23.02.2002 4,588629723 3,996413231 4,588629723 4,302746773 24

So 24.02.2002 4,136201382 4,136201382 4,892578125 4,491647243 24

Mo 25.02.2002 4,411311626 4,00390625 4,677734375 4,341352463 24

Di 26.02.2002 4,648230076 4,411311626 4,916992188 4,700713158 24

Mi 27.02.2002 4,658418179 4,62890625 4,78515625 4,70247221 24

Reports

PIMS

Asset

Monitoring Pattern Detection

Process Flow Charts

KPI-

Monitoring


http://www.scalarvis.de/Losungen/LIMS/LIMS-SV-Kurve.jpg

14

PIMS Data Analysis

Pattern Recognition in PIMS Data

Easy selection of all relevant tags

Easy selection of reference range

Automatic pattern search and result

visualisation

Configuration of match tolerance

Features

Support process personnel in analysis of

process situations and operation conditions

Improve efficiency of root cause analysis for

degradation of product quality/ product

output

degradation of unit efficiency

Identification of unkown dependencies through

historic data analysis

Benefits

Most data analysis problems require

comparison of repeating signal patterns

pattern search is done manually

Application of specialised tool for pattern search in

historc PIMS data

Motivation


15

Batch Analysis

Batch Runtime Monitoring and Analysis

Unit Procedure level Operation level Phase level

Analyze performance of

different units

5. MES-TagungHannover Messe 2013


different operations (of a

unit)


different phases (of an

operation)

11.04.2013

16

Manufacturing KPI Monitoring

What are the current production cost?

How did the new control strategy influence the energy cost?

When did I lastly gain a higher output?

Monthly report

Production amount: 700 t Material cost: 234 €/t Energy cost: 67 €/t

Output??

Cost?? Output

Cost per t of

product

Manufacturing KPI Monitoring


Manufacturing KPIs and Role-based Visualisation

Generic KPIs for most production plants

Production costs

Input of raw materials and energies

Deviation of actual values to planned values

Produced quantity of active agent / capacity

Total runtime of batch process

Specific KPIs for machines and plant units

Yield and selectivity of columns

Efficiency factor of units (e.g. heat

exchanger)

Consumption of raw materials and energies

in plant units

Catalytic activity

Runtime and sequence of single phases of a

batch process

KPI - Cockpit

KPI - Cockpit


BDIS

Aspen IP.21 / Osisoft PI AE SGU SAP

SHR

Asset Effectiveness

KPI-Cockpit

KVP ELP LIMS

Trender

Visual Tile Composer

Intranet Links

Tag Explorer Intranet

Calculations

…

MES-BUS Standard Functionality Visualization Library

MES-Infrastructure platform

AM CPM

Standard MES Applications

MES-Infrastructure and Operational Intelligence Full transparency on all data sources

18 11.04.2013

> 160 PIMS

> 2000 Assets

> 150 plants

> 150 plants

> 150 plants

> 150 plants

> 150 plants

> 60 LIMS

> 150 plants

Standardized

integration of data

sources

Shared

information bus

with context

model (MES-Bus)

Standardized

MES Applications


Simplified Generic MES Landscape

Serves as Template for Tailoring

19 11.04.2013

PIMS LIMS

Vertical Integration

Solution

Manufacturing Operations

Management Application

Horiz. Inte-

gration

Manufacturing Intelligence Solution


20

BASF SE at a glance



Summary & Outlook


Summary and Outlook

Summary

MESs serve as tools to reduce complexity

and achieve operational excellence.

Major benefit of MES is transparency and

automation of process management tasks.

Successful implementation of MES requires

plant-specific tailoring of generic

architectures and tools.

Outlook

Trend towards multi-plant and multi-site

MES

Standardization and consolidation of MES

landscape and interfaces for improved

interoperability

21 5. MES-TagungHannover Messe 2013 11.04.2013

From Data to Information!

Management of production processes (Production, QM, Log., Mainten.) Manufacturing Execution Systems (MES), Plant Information Management System (PIMS)

Optimization of process operation Advanced Process Control (APC)

Supervisory control layer (Control & Monitoring of physical processes) Distr. control systems (DCS), Safety Systems (SPLC)

Field layer Data acquisition und process interference Sensors and actuators

MES

APC

DCS, SPLC

Instrumentation

BASFs Automation Pyramid

Strategic planning and transaction of business processes Enterprise Ressource Planning (ERP), Business IT, SAP/R3

ERP

Data

co

llectio

n

pro

ce

ssin

g

aggre

ga

tio

n

Au

tom

ate

M

on

ito

r

Pla

n

[d]

[h]

[min]

[s]

Information flow

Physical process material flow, enregy flow Plant

23 11.04.2013 5. MES-TagungHannover Messe 2013

mit mes optimierungspotentiale in der prozessindustrie...

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