Mit MES Optimierungspotentiale in der Prozessindustrie...
Transcript of Mit MES Optimierungspotentiale in der Prozessindustrie...
Mit MES Optimierungspotentiale in
der Prozessindustrie erschliessen
Hisham K. Mubarak
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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
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Platzhalter für Bild
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BASF worldwide
Sites
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Regional centers
Selected
production sites
Verbund sites
Most important
research sites
Freeport Geismar
São Paulo
Ludwigshafen Antwerp
Hong Kong
Kuantan Singapore
Nanjing
Florham Park
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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
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BASF SE at a glance
MES as Key for Operational Excellence
Best Practices MES in Process Industry
Summary & Outlook
5. MES-TagungHannover Messe 2013 11.04.2013
“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
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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
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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.
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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!
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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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BASF SE at a glance
MES as Key for Operational Excellence
Best Practice MES in Process Industry
Summary & Outlook
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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
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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
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Batch Analysis
Batch Runtime Monitoring and Analysis
Unit Procedure level Operation level Phase level
Analyze performance of
different units
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Analyze performance of
different operations (of a
unit)
Analyze performance of
different phases (of an
operation)
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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
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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
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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
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> 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
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Simplified Generic MES Landscape
Serves as Template for Tailoring
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PIMS LIMS
Vertical Integration
Solution
Manufacturing Operations
Management Application
Horiz. Inte-
gration
Manufacturing Intelligence Solution
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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
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
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From Data to Information!
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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
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