American Colloid Company: Boost Accuracy and Use of Reliability Data from HMI to C-suites
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Transcript of American Colloid Company: Boost Accuracy and Use of Reliability Data from HMI to C-suites
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
PUBLIC INFORMATION
American Colloid Company: Boost Accuracy and Use of Reliability Data from HMI to C-suite
Wendy Armel, Stone Technologies
Principal MES Analyst
Agenda
Introductions/Technologies Used
Customer Information
Situation/Goals
Project specifics
Wrap Up/ Q&A
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Introduction
Wendy Armel – Principal MES Analyst
Audience – How Many…
End Users
Systems Integrators
Rockwell Automation
Distributor
Other
Experience with
FactoryTalk® Metrics
Business Objects
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What is FactoryTalk Metrics?
OEE and Downtime Tracking
Overall equipment effectiveness (OEE) can provide you with critical insight into how well you are managing your production operations.
Downtime - identify specific causes of inefficiency, including sophisticated methods of analysis that allow you to measure or compare the performance of plants, lines, machines or even individual production teams.
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What Business Intelligence Tools Were Used and Why?
SAP Business Objects Provides for ad hoc analysis at a strategic level
Why use SAP Business Objects? American Colloid Company already uses SAP and owned the BI stack.
Using this product made the data available to a wide audience
The IT Department at American Colloid Company was able to support this solution internally by using a technology they already owned
American Colloid Company needed a way to do strategic level analytics on the data being captured from the FactoryTalk Metrics product
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Customer Information
Plant is located in Lovell, WY. American Colloid Company (ACC) is one of the world’s leading producers of bentonite clay.
Make products for the following: oil drilling
consumer products good (cat litter)
Pharmaceutical
taconite steel
Agriculture
industrial applications
Process: bring in crude bentonite, dry and process and load into rail cars and trucks
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Goals
Reduce Downtime
Increase production rates
Gain visibility into plant operations
Needed more accurate information for strategic and tactical decisions for allocating resources toward continuous improvement.
The goal was to improve efficiency and reduce costs.
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Challenges
Focusing everyone on the right (biggest) issues
There are four crews running 12 hour shifts. Communications between the crews were difficult to keep updated. Each crew had a different perspective on what the issues were.
Needed to change the culture from using tribal knowledge to using data from an automated collection system - FactoryTalk Metrics
A previously installed automated data collection system was ineffective. The end users were skeptical of another solution.
Integrating manually recorded data from both domestic and international locations.
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Project Approach
Implemented small pilot
Refined pilot to provide for base configuration
Expanded base configuration
Implemented data warehouse to allow for high level analytics
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Pilot
Stone Technologies and FactoryTalk Metrics were put on trial to deliver a solution that could improve our reliability.
Implemented on one Mill process line (work cell)
Began receiving automated emails of key reports to become aware of the data.
Root Cause Analysis report – reviewed end of each shift. Reviewed to see if there are indication of unexpected issues.
Production Summary– reviewed daily. Provided information on productivity
Downtime Summary – reviewed daily. Provided insight into downtime.
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Pilot – Root Cause Analysis AG
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Pilot – Production Summary AG
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Pilot – 24 Hour Downtime Summary AG
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Pilot Refinement
Refined machine states and down time reasons
Linked data into MSAccess to allow ad hoc analysis by reliability team
Refined automatic notifications Added email notification to key personnel when a downtime reason changed
Determined the only automatically delivered report needed was the Root Cause Analysis report
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Expansion
Expanded data collection to the following:
3 Mills
2 Dryers
3 Screening Systems
Geosynthetic clay liner
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Data Warehousing/Ad Hoc Analysis
After analyzing data in MSAccess, it was determined what data was needed at the strategic level
Categorized the machine states and events into buckets that impacted the asset availability
Total hours of downtime
Number of occurrences
Production rate
Corporate IT implemented a data warehouse Identify the data and define the summarization criteria
Set the automated routine to extract the data to keep data fresh
SAP Business Objects applied for ad hoc analysis
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Asset Availability AG
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Availability by Work Cell
Shows Final compiled data warehouse data
Packaging data is manual data that was merged into the data warehouse
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Detailed Events For Selected Bar AG
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Downtime Hours
This chart allows allocation of resources
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Downtime Occurrences
Selected the “shock switch” bar and the following details are displayed.
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Production Rate
Actual vs MAC (Maximum Achievable Capacity)
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Results
American Colloid Company realized results Focused resources on the correct areas
78% - 94% Asset Availability
Increased MAC across the plant by 30%
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Benefits
While the project was successfully implemented by Stone, it is critical to the customer that they not be reliant on Stone for future support
Stone personnel (even ones new to the system) can support the standard configuration
Should the customer ever need it – there are MANY other integrators who can support the standard FactoryTalk Metrics implementation
Not stuck with a single provider as they were with the prior solution
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Benefits of FactoryTalk Metrics - Customer
Support is easier if new people are introduced to the project
TIME – standard objects shorten implementation time frames significantly
MONEY
Out of box cost
Ongoing support
Integration
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Lessons Learned
People cannot accurately estimate what is taking place in a production environment.
Prior to implementation – ~60% accuracy
Automated solution - ~95% accuracy (time is 100% accurate)
Having data to support the issues, allows operations, maintenance and quality to focus on the same issue instead of working against one another, solving what they think the problem is.
Interdepartmental communications are more efficient and having the correct data takes the emotion out of decisions. When the teams start to succeed, people are more eager to work together. Success is contagious
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Take Away
When you are on an effort to improve, if you solve the wrong problem, you wind up with two problems. The original, plus the one you created.
FactoryTalk Metrics provides the data to focus on the right problem
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Summary
Goals
Get new data acquisition solution up and running quickly and efficiently
Keep the solution cost effective
Approach
Stick to standard configuration as much as possible
Results
Streamlined, repeatable solution that provides valuable data to multiple levels of the organization
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CO
MP
AN
Y OV
ERV
IEW
Stone Technologies
$15M 2013 revenue
54 full time employees
Average 20% year over year growth for past 10 years
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Stone Technologies, founded in 1996, is a national system integrator providing automation/control, information (MES) and operational consulting solutions. Based in St. Louis, MO with resources in 15 states/ 1 province.
Employee Business
Satisfied people deliver successful projects and provide long term continuity
Stone Technologies long term relationships built on performance, trust, & keeping promises.
Average 95% employee retention rate for the last 10 years The technical staff has an average of 22 years of experience
Of our top 20 clients (by services revenue) since the inception of the company 15 years ago: Doing business with ALL of them today
Average relationship is over 9 years Average of 50 projects per client Average adding 2 – 3 new clients a year
We have paid employee bonuses every year since inception
Our best revenue generating tool is the successful delivery of projects
CO
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CT U
S Contact Information
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Wendy Armel - Principal MES Analyst
Office: (972) 395-1627 Cell: (727) 244-5588
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
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