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