Driving Operational Performance by building Manufacturing Capability one step at a time…..
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Transcript of Driving Operational Performance by building Manufacturing Capability one step at a time…..
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Driving Operational Performanceby building Manufacturing Capability one step at a time…..
Phillip Terlesk
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2Copyright © 2013 Rockwell Automation, Inc. All rights reserved.
Agenda
2
Opportunity
Present State For Many
Manufactures
Collaborate to leverage the Opportunity
Customer Use Case
Questions
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3Copyright © 2013 Rockwell Automation, Inc. All rights reserved.
Global population will exceed 7 billion
More than 70 million will enter the middle
class
Middle class adding $8 US trillion to consumer spend
BEST IN CLASS DEMANDS
Operating Excellence
Compliance
Dynamic Value Creation
$8
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4Copyright © 2013 Rockwell Automation, Inc. All rights reserved.
Growth Matrix – Wine is a STAR!
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Growth Matrix – Infant Formula
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Infant Formula / Nutritional Powders
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Value Add will drive growth
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Adding Value will build export $$
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9 9
v
MANUFACTURINGOPERATIONSCAPABILITY
Product Innovation
Reduce Waste
Process Innovation
Raw Materials
Time
People
Chemical / Energy
Capability To Bring Profitable Products to Market Faster
Dynamic Value CreationSucceeding in a Changing Market Place
Market Data
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10Copyright © 2013 Rockwell Automation, Inc. All rights reserved.
Agenda
10
Opportunity
Present State For Many
Manufactures
Collaborate to leverage the Opportunity
Customer Use Case
Questions
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11Copyright © 2013 Rockwell Automation, Inc. All rights reserved.
Questions We Face On a Daily Basis ?
Did we stay within range on all Quality parameters during
Fermentation
Did we meet the CIP targets during the cleaning cycle?
• Temp• Time
Have I completed &
signed off all the preflight checks before starting the new batch?
Have we set up our coders correctly
Are our labels and packaging material correct & serialised
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Business, IT & Automation Investment may not be 100% Aligned
Control Systems
HMIs
ManufacturingOperationsManagement
Alarms/Events
Other Database s
Computerized Maintenance Management Systems
Performance Management
Quality Systems
ProductionHistorians
Laboratory Information Management Systems
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Process, Packaging &
Safety Automation
Building Capability one investment ata time
Manufacturing Operations
Management
ERP
Manufacturing Intelligence Process OptimisationChange & Asset Management
StandardOperating &Procedures
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For the Operators Monitoring process to keep production
running Identifying relationships to optimize the
process
Operator
For the Production Manager Schedule, track production activity Way production is running, ways to improve
Production
For the Engineering / Maintenance Manager Keeping plant running Predicative maintenance, asset
optimization
Engineering
For the Quality Manager How product was made, ensure
compliance Ways to improve product and yield
Quality
For the Executive Costs, schedules, production output Financial indicators, sustainability
Plant Mgmt.
Deliver the correct Information
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Agenda
15
Opportunity
Present State For Many
Manufactures
Collaborate to leverage the Opportunity
Customer Use Case
Questions
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Collaborate to Prioritise Objectives & Align Capability
ExecutionInnovationCompliance
Performance FocusLine & Site Specific
Reports&
KPI’s
Business DriversBusiness Drivers Align CapabilityAlign Capability
PeoplePeople
ProcessesProcesses
MaterialMaterial
EquipmentEquipment
Quality / Yield Quality / Yield
ThroughputThroughput
EnergyEnergy
xxx $$$ xxxxxx $$$ xxx
High levelBusinessObjectives
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17Copyright © 2013 Rockwell Automation, Inc. All rights reserved.
Agenda
17
Opportunity
Present State For Many
Manufactures
Collaborate to leverage the Opportunity
Customer Use Case
Questions
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APC & Industry Use - Case
Phillip TerleskSales Executive
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Rockwell Improves Manufacturing Processes
Enhance Profitability through:- Improve Product Quality
Minimize variabilityReduce deviation from
specifications
- Increase ProductionUnlock capacity Maximize
throughput
- Reduce Manufacturing CostsUse less energy per unit of outputMaximize yield
MPC Goal – High ROI, robust, operator friendly solutions that deliver long-term value
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Analysis
Prediction
Control
Optimization
Soft Sensors
Model-based Applications Approach
A Hybrid Model explains or emulates
the behavior of a process.
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21Copyright © 2013 Rockwell Automation, Inc. All rights reserved.
Pavilion8 Model Predictive Control
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Controller executes at 5 sec to 1 min intervals
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Soft Sensors (Virtual Online Analyzers or VOA)
… neural networks can fit general non-linear
relationships
input
A input B
outpu
t
artificial neuron with weight parameters
VOA
Calcs
ProcessData
LabData
Product Quality
Process Parameter
Neural Networks Replace sparse, or infrequent, feedback from Lab or analyzer
RecircFeedFermRXN HHHH Heat and Material Balances
RXNHfEtOH Traditional Empirical Correlations
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How APC Enables Operational Objectives
Minimize operational variance
DV CV
Transition effectively
CV
Follow operational plan
CV
SPECIFICATION OR LIMIT
BEFORE MODEL PREDICTIVE CONTROL
WITH MODEL PREDICTIVE CONTROLAND OPTIMIZATION
KE
Y T
AR
GE
TBENEFIT $
Reduce Variability 30 – 50%
Achieves Uplift - closer to spec or performance limit whilst managing the process within constraints and safety margins
The Business Value is Achieved by
“raising the bar”
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Operator Interaction with a Standard Regulatory Control System
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Process Lab
PID PIDPID PLC/DCS
?!?!? Step A,D,B,C
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Operator interaction with aModel Predictive Control System
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Process
Soft Sensor MPC
Lab
Pavilion8
PID PIDPID PLC/DCS
ProductionTarget
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Milk Powder Processing
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• Farm Cows
• Tankers / Rail
• Raw Milk Silo Storage
• Separation into skim milk and cream
• Standardization to specifications by combining skim milk, cream, and lactose or permeate
• Falling Film Evaporation
• Spray Drying
• Powder Packing
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27Copyright © 2013 Rockwell Automation, Inc. All rights reserved.
Plant Pax - Visualisation
ERPERP
MOM
SCADA
Controls & SafetyRo
ckwe
ll FT
Hist
oria
n -
Repo
rting
and
Too
ls
Receiving Area & Raw Milk Silos
Milk Separation into Skim Milk & Cream
Utilities Evaporation / Drying / Fluidbed
Packaging /Logistics/Mass Serialisation
Quality
Production Landscape Future Automation Landscape
Dairy Solution
CPGSuite
Standardization to specifications by combining skim milk, cream, and lactose or permeate / Milk Treatment
Pavilion Moisture Optimisation Powder Drying
Pavilion Fat / ProteinOptimisation
CPG Suite Labeling / Serialisation
Milk Treatment
Packaging
Plant Pax - Logix
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Scope for both Protein & Fat Optimisation & Pavilion8 Dryer & Evap MPC
Wholemilk Separation Pasteurization
Permeate / Lactose etc
Cream
ProcesScan™ FT
Product In8-15% solids
Product Out45 -55% solids
Cold Air
Hot Air
Hot Air
Powder Out
Solids In
HP Pumping Drying
Standardized buffer Storage
Butter Processing
Standardizing Streams
Rockwell - Protein & Fat Optimisation Solution
Pavilion8 Protein & Fat Optimisation Analysis – this overview
Rockwell’s MPC Solution-Dryer & Evap Optimization
Pavilion8 MPC Dryer & Evap Optimisation
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29Copyright © 2013 Rockwell Automation, Inc. All rights reserved.
Dairy Standardisation Solution
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• Rockwell’s Pavilion8 Model Predictive Control (MPC) platform provides a closed loop standardising solution with superior targeting of final powder Fat and Protein composition.
• Minimising giveaway of protein and fat in the standardisation process optimises yield providing substantial financial benefit.
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Dairy Standardisation Solution Performance and Visability
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Moisture benefits, control performance & how hard moisture is pushed
Distribution curve comparison (mean & standard deviation) against baseline
Accepted moisture lab value against specification limit and controller target
Cp – how good is distribution within limits: Cpk – how centre is the distribution within limits
Standard deviation improvement against baseline
Downloadable & accepted moisture lab values report
A key Differentiator
Visualisation: Performance Metrics
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Dairy Standardisation Solution Benefits
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• Composition variability reduction of 50% or greater
• Tight compositional control allows fat and protein targets to be driven to the specification minimums.
• Superior final powder compositional targeting.
• Performance visualisation facilitates proactive decisions
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