Automation Trends for 2011 ARC Forum 2011, Constantino Seixas

Transcription

1 Automation Trends for 2011 ARC Forum 2011, Constantino Seixas Copyright Accenture All Rights Reserved. Accenture, its logo, and High Performance Delivered are trademarks of Accenture.

2 Automation Trends in Integration of Information 2. Global MES Template 3. Production Optimization 4. Agribusiness Automation 5. Cyber Security 6. Operational Intelligence Centers Implementation Copyright Accenture All Rights Reserved 2

3 #1 The gathering Integrating information across disparate sources Locate & Valuate Asset Development Inbound Logistics & Services Mining Operations Beneficiation Outbound Logistics Market Find/acquire better assets more quickly Online sooner at lower cost Improve SC efficiency and reduce costs Increase up time and yield at lower costs Provide best transportation Enhance effectiveness and margins Information is very disperse in a industrial environment A range of IT systems from different suppliers implemented across the production processes and supply chain increases the risks in securing accurate information in a timely manner, increases inefficiencies and reduces response time. The accumulative result: An impact on costs and competitiveness. Accenture believes business needs to make smarter investments, for business intelligence and analytics throughout the value chain will drive industrial IT integration to grow exponentially. Accenture is working with mining, metals, CPG and manufacturing companies to integrate from ERP to Instrumentation across the whole supply chain. Copyright Accenture All Rights Reserved 3

4 #2 Not lost in translation Standardizing practices and templates globally Successful mergers and acquisitions come with successful post-merger integration Companies around the world are initiating programs to standardize ERP practices (ERP Global Template), dispersed MES implementations by different business units and operational functions, and varied supply chain management and production management processes Accenture is responding to our clients need for standardization by providing consulting services for business models, MES Blueprint, supplier selection, and MES implementation. We are drawing on our assets and capabilities such as the Accenture High Performance Business Processes, developed for the different industries (mining, metals, utilities, etc.), to help scope out the standardization initiatives. Copyright Accenture All Rights Reserved 4

5 #3 A method to getting more Production optimization and asset utilization The pressures of producing more from the same assets whilst reducing costs, a concern of production managers, will take front and center stage Main objectives are: Variability reduction (quality, process variables, OEE, production, etc.) Improve Throughput Improve Quality Reduce Costs Accenture applies a combination of Lean Six Sigma + Process Optimization to troubleshoot processes and find Quick Wins opportunities Technology/Tools People Methodology Copyright Accenture All Rights Reserved 5

6 Use modern tools, leading methodologies, and skilled people to continuously improve assets utilization Integrated Centers for Asset and KPIs Monitoring: From Information to Action Control Loop Monitoring Process Assets Control Systems Configuration DCSs Servers, Comm Assets, Networks Instrumentation Control Loops Process Troubleshooters Energy Monitoring Utilities, Energy and Emissions Intelligent MCC Field Networks Historians Process Assets Copyright Accenture All Rights Reserved 6

7 #4 Tracking the harvest Agribusiness is automating every step Increasing the level of the business performance and external forces such as environmental and health/safety awareness, have producers striving to better manage their production and supply chain processes The agribusiness has increasingly automated from farm to final product Accenture sees the uptake of automation in soya bean, corn, oranges, coffee, and sugar cane to name a few Operational Costs Breakdown Sugar & Ethanol Plant Brazil 100% 65% % 18% 0.07 Total Cost Agriculture Industrial Sales, Logistics & Admin Copyright Accenture All Rights Reserved 7

8 Accenture is currently working on a couple of sugar cane harvesting information management projects. A sugar cane production chain includes the farm, sugar and ethanol processing plant and cogeneration plant consuming cane bagasse The solutions we are implementing encompass: Automatic data collection Telemetry Cane Harvesting Report Precision Agriculture Center of Agricultural Operations Accenture created a Center of Excellence in agribusiness in São Paulo, Brazil 100% 65% 17% 18% Copyright Accenture All Rights Reserved 8

9 #5 Weak links and leaks no more Cyber security Stuxnet and other threats put information security on the world stage Stuxnet was a wake-up call for automation as managers believed the industrial environment was safe of viruses Companies are increasingly assessing and evaluating their IT architectures to mitigate risks. The overarching goals of these initiatives are improved performance and greater business value Accenture is helping organizations secure their data, protect identities and build trusted relationships with their customers, various constituencies and partners Copyright Accenture All Rights Reserved 9

10 #6 A war room for operational intelligence Analytics, knowledge and operational centers to accelerate performance The questions businesses ask are: What information to we have? What do we do with it? How do we turn it into useable and actionable information to distance ourselves from the competition? Accenture has built Operational Intelligence Centers (OICs) for a number of forwardinglooking businesses. These centers are not control rooms they are analytic centers conceived for information-based decisionmaking An OIC brings together in the same war room people with different skills: production planners, infrastructure, maintenance, production, etc. A center can be located at a plant or remotely, where it is generally shared between several plants or production chain units Copyright Accenture All Rights Reserved 10

11 OICs extract data from all application sources: DCSs, SCADA + PLC, Historians, MES, APC systems, LIMS, etc., and formats the data for decision-making It forces people to act before the fact (predictive capability) or react faster after the event It allows the sharing of expensive resources between plants of the same production chain or geographic location (hub of plants) It provokes the benchmarking of results between plants creating knowledge and best practices Copyright Accenture All Rights Reserved 11

12 Thank you Copyright Accenture All Rights Reserved 12