Enabling
Plant Performance Benchmarking
in a multi-site environment
Wim ten Dam
[email protected]
Bert Wissink
[email protected]
Agenda
• Introduction
• Business Challenge
• Solution Description
• Benefits
• Future Plans
Akzo Nobel – Atos Origin – Enabling Plant Performance Benchmarking
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Introduction
• Akzo Nobel Base Chemicals BV
• Atos Origin Nederland BV
Introduction
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Akzo Nobel
• Activities in 80 countries
• Employing 62,000 people
• Consolidated revenues 2004 totals € 12.9
billion
• Headquarter Arnhem, the Netherlands
– Market-driven and technology-based
– Serving customers throughout the world with
healthcare products, coatings and chemicals
Introduction – Akzo Nobel
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Akzo Nobel Base Chemicals BV
• Business Unit, headquarter Amersfoort, the
Netherlands
• 2,000 employees
• € 800 million sales
• Produces Energy Cogeneration, Bulk Salt,
Chlorine-alkali products and derivatives
• Our products play a vital role in a variety of
industries and in many day-to-day articles like
glass, textile, detergents, paper, plastics,
pharmaceuticals and disinfectants.
Introduction – Akzo Nobel
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Akzo Nobel Base Chemicals BV
Production sites:
• 3 Energy Cogen
• 3 Bulk Salt
• 5 Chlorine
• 2 Ferro-Chlorine
Introduction – Akzo Nobel
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Production Outline
Introduction – Akzo Nobel
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Atos Origin
• A leading IT services company providing
business consulting, systems integration and
managed operations that improve the
effectiveness of its clients’ businesses
• 2005 FY revenue € 5.5 bn
• Over 47,000 employees
• Presence in 40 countries
• Industry (Public Sector, Finance, Telecom/Media,
Discrete mfg, PILS, Retail)
Introduction – Atos Origin
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Atos Origin
Business Mix
Geography
Others 9%
Consulting
8%
Spain 5%
Italy 6%
Systems
Integration
41%
Managed
Operations
51%
France
28%
Germany + CE
10%
(*) Of which 14%
is recurring
business
(*) Application Management
Benelux
21%
UK
21%
Industry
Others (*)
6%
Retail 10%
Public Sector
PILS (**) 8%
& Utilities
26%
Discrete
Manufacturing
Finance
12%
Telecom
19%
& Media
19%
(*) Including Transport
(**) Process Industry & Life Sciences
Introduction – Atos Origin
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Atos Origin
UK
6,500
6,900
France
12,400
14,000
North America
1,000
750
South America
1,300
1,700
Spain
4,800
5,400
Benelux
9,300
Central Europe
2,600
3,750
Italy
3,100
2,900
Asia/Pacific
2,000
2,500
Middle East &
Africa
500
Total Employees 47,700
Introduction – Atos Origin
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Business Challenge
• What were our business issues?
• Where did we come from?
• What were our objectives?
• Where do we want to go?
Business Challenge
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What Were Our Business Issues?
• No harmonized definition of plant data
• Different legacy MES systems or none at all
• No uniformity on Production Accounting
• Manual transfers of production information
• No “bird’s-eye view” on overall performance
• No possibilities for plant benchmarking
• No common “manufacturing language”
Business Challenge – Business Issues
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Where Did We Start From?
ERP
SAP
Navision
2002
Progres
MES
Excel
Excel
Fox-com Fox-com PI3
DCS
Foxboro Foxboro Honeywell
ABB
Emerson
Emerson Emerson
DeltaV
RS/3
Plant
Chlorine Chlorine Chlorine
RDM
DZL
HGL
Netherlands
Chlorine Chlorine
IRN
BIT
Chlorine
SHL
Germany
Sweden
Business Challenge – Point of departure
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What Were Our Objectives?
• Replace Progres in NL (3 plants)
• Replace Navision in GE (2 plants)
• Harmonize all 6 chlorine plants on plant
information level (MES)
• Take into account:
– 2 old plants will be shutdown within 2 years
– 1 new plant will be started up within 1,5 years
Business Challenge – Objectives
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Why Did We Choose PI?
• Already present at 1 plant
• Used at other plants within Akzo Nobel
• Commercially available standard product
• Proven technology
• Numerous and proven interfacing possibilities
• Lowest TCO of alternatives
• Core business for supplier
Business Challenge – Why PI?
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Surprises During The Project
• Reorganization within Akzo Nobel:
– 3 BU’s (Energy, Salt and BC) were merged
– Scope became more extensive
• MCA plants of Functional Chemicals want
to join the Base Chemicals MES program
Business Challenge – Surprises
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New Challenge
• 3 Bulk Salt plants to add
• 3 Energy Cogeneration plants to add
• 2 MCA plants to add
• 2 additional SAP systems to merge
• 6 additional DCS systems to connect
• > 10 additional third party systems to connect
• 8 additional legacy systems to replace
• 1 additional country to take into account
Business Challenge – New Challenge
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Now Where Are We Starting From?
ERP
Navision
SAP BC
SAP FC
SAP Salt
SAP Energy
2005
Progres
MES
Excel
Progres
PHD Excel
Excel PHD
PHD
SQL
Fox-com Fox-com PI3
DCS
PI2
HoneyABB Emerson Foxboro FoxboroHoneywell Emerson Fisher Valmet
ABB
well
Foxboro
DeltaV RS/3
PHD
Honey- Honeywell
well
Fox-com
Foxboro
Plant
Chlorine Chlorine Chlorine ChlorineChlorineMCAChlorine MCA Salt
IRN
BIT
DZL
HGL RDM HGL SHL SHL DZL
Germany
Netherlands
Sweden
Salt
HGL
Salt
MGR
Energy
DZL
Netherlands Denmark
Energy Energy
HGL
RDM
Netherlands
Business Challenge – New point of departure
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Where Do We Want To Go?
ERP
SAP BC
SAP FC
2009
PI
MES
DCS
ABB
Emerson
Emerson
Honey- Emerson Emerson
Metso
DeltaV
RS/3
well
HoneyABB
well
Honey- Honey- Honeywell
well
well
Plant
Chlorine Chlorine Chlorine
IRN
BIT
DZL
Germany
MCA
DZL
Chlorine Chlorine
RDM
SHL
Netherlands
MCA Salt
SHL DZL
Sweden
Salt
HGL
Salt
MGR
Energy
DZL
Netherlands Denmark
Energy Energy
HGL
RDM
Netherlands
Business Challenge – Goal
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Solution
• Central PI Server with high availability
• Local PI Interface Nodes (high availability)
• Local, but uniform, Production Accounting
• Local, but uniform, reporting
• Scripted (WXP) client software (PB, DL)
• As much as possible standard PI software
Solution
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Issues
• Finding a suitable solution for Production Accounting
•
•
•
•
Multiple plants on 1 PI system
Differences in language and culture
Availability Akzo Nobel employees for MES projects
Network load vs. capacity
• Connecting Process Control Layer to office LAN
• Parallel processing can take long
• What is the real truth: the old system or the new one?
Solution – Issues
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Issues
• Finding a suitable solution for Production
Accounting
Solution – Issues
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Issues – Finding A Suitable Solution
For Production Accounting
• Production Accounting consists of
– Daily and monthly calculations for:
• Consumed utilities and raw materials
• Produced chemicals
• Delivered chemicals to customers
• Inventory (tank levels  tonnes of product)
– Daily and monthly reporting on the above
– Updating SAP with the above
Solutions – Issues – Production Accounting
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Issues – Finding A Suitable Solution
For Production Accounting
• PI ACE:
• Too complex programming for end-users
• Too much work-arounds needed
• Calculation sequence is not automatically managed
• PI Analysis Framework:
• Too much configuration needed for this purpose
• Too high TCO for this purpose
• But, still evaluating PI AF benefits for other purposes
Solutions – Issues – Production Accounting – Alternatives
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Issues – Finding A Suitable Solution
For Production Accounting
• Solution: Build something yourself
• Production Accounting Calculation Engine (PACE)
• Based on Microsoft tools and OSIsoft PI SDK
• Formulas stored in local database (MS Access)
• Using Access as a calculator
• Calculation results stored in PI Archives
• Reporting with Excel and DataLink
Solutions – Issues – Production Accounting
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Issues – Finding A Suitable Solution
For Production Accounting
• Benefits:
• Easy management of calculations by end-users
• Automatic management of calculation sequence
• Simple validation of results
• Easy manual changes and additions of data
• Simple possibilities for recalculations
• Free to change functionality
– (like adding Formula Change Management)
Solutions – Issues – Production Accounting
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Issues – How Were Other Issues
Solved
• Short PB + DL reference manuals in local languages
•
•
•
•
Agree upon tag naming convention and stick to it
Implement PI security on tags and data (proxy)
Prioritize network traffic for PI and improve band width
Implement hardware firewalls to connect Process Control
Layer to office LAN (but, still a burden)
• Fixed core project team for all rollout projects
• Workload shift from Akzo Nobel to Atos Origin
Solution – Other issues solved
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Products Used
• PI server software, including DAP
• PI interfaces: OPC (2), PI-to-PI (4), PHD (2),
RNI, DDE, ABB-IMS
• ProcessBook, DataLink, SDK
• Custom build interfaces: File Transfer, legacy
systems
• Custom build applications: PACE, Manual Input
Solution – Products used
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Solution – Examples
Overall
performance
overview
Solution – Example
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Solution – Examples
• Insights in consumptions, production and
deliveries
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Solution – Examples
• Insights in stocks
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Solution – Examples
• Production Accounting, Formulas
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Solution – Examples
• Production Accounting, Calculation
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Where Are We Now?
ERP
SAP BC
SAP FC
2006
PI
MES
DCS
ABB
Emerson
Emerson
Honey- Emerson Emerson
Metso
DeltaV
RS/3
well
HoneyABB
well
Honey- Honey- Honeywell
well
well
Plant
Chlorine Chlorine Chlorine
IRN
BIT
DZL
Germany
MCA
DZL
Chlorine Chlorine
RDM
SHL
Netherlands
MCA Salt
SHL DZL
Sweden
Salt
HGL
Salt
MGR
Energy
DZL
Netherlands Denmark
Energy Energy
HGL
RDM
Netherlands
Business Challenge – Current Status
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Benefits, So Far
• Harmonized definition of plant data
• Uniformity on Production Accounting
• Common “manufacturing language”
• Excellent possibilities for plant benchmarking
• Better view on overall performance
• Better view on consumptions, stocks and
deliveries
• Improved Production Planning
Benefits – Current Status
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Opportunities
• First step for improvements is made
• People are experiencing the power of PI
• New possibilities will be discovered
Benefits – Opportunities
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Future Plans
• RtWebParts to make PI data available from
every seat at every site
• PI Batch
• PI SQC within ProcessBook
• Investigate feasibility of integrating PI with
SAP Plant Maintenance
• Investigate feasibility of other opportunities still to
be found
Future Plans
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Conclusion
• We have certainly reached value now
• We expect to get more value over time
Conclusion
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