Production and process managers have become empowered knowledge workers. ABB's solution for Production Information Management drastically simplifies production management by enabling performance monitoring, downtime management and maintenance support, as well as providing statistical production analysis tools.
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Performance Monitoring / Downtime Management / Maintenance Support / Statistical Production Analysis / Excel Add-In / Mass Balancing
The key to production planning is the on-line access to information without delays. IndustrialIT for Production Information Management provides reliable reports on the plant production situation: product stocks, capacities of process equipment, availability, etc.
Performance Monitoring
The performance monitoring functionality provides functions including running plant overview, industry specific calculating and reporting capabilities for production, and material storage. Reporting using standard formats is simply a matter of clicking.
Identification of the influences of process parameters on product quality, production capacity, energy consumption and emission levels, is now easier than ever. Powerful tools including
- production tracking and reporting
- process operations monitoring and reporting
- KPIs, including OEE calculations and presentations
- material storage management
- energy and emission reporting
to enable process analysis are available at the click of a mouse button. After all, successful process information is key to your plant operation.
Process operation support helps process managers by identifying the influences that process parameters have on product quality, production capacity, etc. It combines production related data, process variability, energy indexes, run-time quality parameters, etc in comprehensive process operation reports.
Production information in the form of minute, hourly, daily, shift, etc. values are automatically tracked and consolidated are available for automatic input to the SAP system after validation.
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Downtime Management / Maintenance Support
Reducing down-time and keeping up production capacity is vital for any production plant. And correct information is the key. Most downtime and maintenance administration solutions on the market miss the automatic link to real-time information.
ABB's Industrial
IT solution for maintenance support makes sure you know for certain what your most costly problems are, taking the guesswork out of maintenance by integrating facilities for easy identification of failing equipment. Identification of failing equipment is based on event and alarm statistics. Multi-dimensional Pareto analysis is used to find out the real and most costly weak points in the production process and provides support for forecasting the next maintenance event. Maintenance events of specific process equipment are forecasted by using equipment running hours, production totals, cumulative energy utilisation, etc.
In a modern process control system, complete collection of all downtimes can be easily realized. Identification and categorization of stop causes requires an additional clarification, experience, and expertise. The stop log function is used to enable a static evaluation of the downtimes of main plant sections such as grinding mills. Based on the runtime collection and supervision, the downtimes are recorded and their causes are acquired and evaluated. Multi-dimentional Pareto analysis is based on predefined plant specific causes from the Fishbone diagram. The reasons and codes catalogue for downtime and stops can be downloaded directly from your ERP system.
Direct integration of information into your business maintenance administration system is an obvious advantage. Transferring stop logs, running hours, down time statistics, etc SAP’s modules are a matter of plug and play. Although automatic, it allows for validation, manual correction and approval by the maintenance and production manager before transfer. Through interfaces like these, ABB protects your long-term investments by tying into your existing standards!
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Statistical Production Analysis / Excel Add-In
ABB provides powerful tools to effectively monitor and analyze quality related process variables. This information enables operators to compensate or to eliminate assigned causes before out-of-specification product is produced. In Knowledge Manager Statistical Production Analysis, trend functions X Chart, EWMA chart and CUSUM chart have been selected to match manufacturing process specific requirements. Statistical Production Analysis also provides X-Y graphs (scatter plots) to plot two variables against each other to see the possible correlation between them and histograms for easy view of statistics of run-time quality measurements. Cross correlation calculation with time lag compensation is an important tool to get meaningful information out of your process data.
In Statistical Production Analysis, the quality is emphasized as a process characteristic. It is believed that if the process is controlled and improved, product quality will be maximized automatically. Therefore, product specifications are normally left out of quality improvement activities until the process has first been optimized. After the process has been stabilized, product specifications are compared to process control limits to determine if the process is capable of producing the product to these specifications.
Statistical Production Analysis control charts contribute to process and quality improvement in three ways:
- They provide a picture of the state of the process and the improvement of the quality over time;
- They provide information for correction of assignable causes and for improvement of the process;
- They indicate the process capability - what it is actually capable of doing during assignable cause correction and process improvement activities.
To enable further reporting and analysis, the Knowledge Manager also provides an Add-In to Microsoft Excel.
This enables you to easily make queries on the client PC directly from EXCEL spreadsheet, without the need of writing SQL commands to access the Knowledge Manager information.
The Add-In uses HTTP to retrieve data from any Knowledge Manager server (no ODBC and SQL net required), including access to multiple servers simultaneously.
It is very practical for user specific “ad hoc” reports, and allows you to apply any standard EXCEL functions to process the production information.
Importantly, it is a bi-directional link, which can be easily used for bulk data correction in the Knowledge Manager.
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Mass Balancing
The primary objective and application is data reconciliation through mass balancing: reconciliation of stream phase distributions and flow rates, as well as complete and incomplete analyses of the phase of interest. Estimation of non-measurable or missing variable values is another application. The system performs a sensitivity analysis to determine the accuracy of its own results.
Production Mass Balancing, the reconciliation of data on cumulated tonnage, is typically done every shift, batch, day, week, month, etc.. The necessary real-time and historical information on process measurements and assays is automatically retrieved from the production data warehouse environment. The reconciled information is stored back for future reference, analysis and metallurgical accounting.
Indicative Mass Balancing is the automatic and on-line reconciliation of real-time data. Data from instrumentation and assays always come with an unidentified error. Indicative Mass Balancing provides more accurate and validated information for process monitoring and optimization, consistent, continuous and instantaneous.
Industrial
IT for Mass Balancing empowers many functions in the plant:
- Operators have access to accurate process variable values, some of which cannot be measured;
- Process engineers tune process equipment and validate process efficiencies computed from coherent and reliable numbers;
- Control engineers tune sensors, controllers and select setpoints from reliable data;
- Production managers receive frequent and accurate process efficiency estimators;
- Executives are kept informed correctly about ongoing production with almost real time data.
This solution is empowered by Algosys' powerfull KM Bilmat engine. Please also have a look at
http://www.algosys.com
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