Mit MES Optimierungspotentiale in der Prozessindustrie erschliessen. Hisham K. Mubarak

Transcription

1 Mit MES Optimierungspotentiale in der Prozessindustrie erschliessen Hisham K. Mubarak 1

2 BASF SE at a glance MES as Key for Operational Excellence Best Practice MES in Process Industry Summary & Outlook 2

3 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 Platzhalter für Bild In 2012, BASF filed for around 1,170 new patents worldwide 6 Verbund sites and around 380 production sites 3

4 BASF worldwide Sites Antwerp Florham Park Ludwigshafen Freeport Geismar Nanjing Hong Kong Kuantan Singapore Regional centers Selected production sites São Paulo Verbund sites Most important research sites 4

5 Verbund site Ludwigshafen The largest integrated chemical complex in the world 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 5

6 BASF SE at a glance MES as Key for Operational Excellence Best Practices MES in Process Industry Summary & Outlook 6

7 Achieving Operational Excellence (OpEx) is a Continuous Challenge for Plant Operators 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. 7

8 Maturity MESs are key to create transparency, to analyze opportunities and to move towards Operational Excellence Operations have reached maximum fit with business strategy Operations are adaptive maximum value creation through adaptability Operations are learning cont. improvement as basis for development Operations are stabilized with respect to safety, quality, availability etc. Operations are transparent Operations are optimized improved knowledge and balanced resources KPIs for improvement levers, visual mgmt, etc. Time 8

9 Reality: Complexity is overwhelming process managers Process analysis Analysis of optimization hypothesis require manual data integration from several systems (LIMS, PIMS, DCS alarms, SAP,...) Help!! Digital Tsunami Non-productive tasks reduce time available for process optimization Need for complexity management 9

10 MES Support Management and Optimization of Operational Processes 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! 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 componentand material-level traceability, genealogy, and integration with process history. MESs coordinate the execution of work orders with production scheduling and enterprise-level systems. 10

11 Manufacturing Execution Systems Need to be Tailored for Each Plant Production planning Cost Calculation Sales and Delivery Reclamation Management Business focus Operative Condition Produktions- Based und Instandhaltungsplanung Maintenance Production Documentation Bewertung der Prozessund Anlagenperformance Process Data Analysis Batch Monitoring and Analysis Reporting von Verbrauchen, Detailed Scheduling Produktionsmengen und Beständen Information Integration KPI-Monitoring Effizienzsteigerung und Prozessoptimierung... Plant Asset Management Quality Driven Process Control Shift book and report book Operational focus Tank farm control PCS FPLS/ Filling warehouse DCS LIMS Control TCS control TCS Raw material production lab filling Warehouse and delivery 11

12 BASF SE at a glance MES as Key for Operational Excellence Best Practice MES in Process Industry Summary & Outlook 12

13 Plant Information Management Systems (PIMS) serve as standard data source for MES applications SAP-Integration Reports Februar Messstelle P_1170.X P_1811.HDAC 06: :48: :20:26 4, AUTOMATIK BAR Druckreglung Druckregelung Wertermittlung Min Max Laufzeit TagesAnfang Mittel Vorgabe 3,8 4,5 AUTOMATIK , , , So 5 24 Mo , , , , Di , , , Mi , , , , Do , , , , Fr , , , , , Sa , , , , So , , , , Mo , , , , Di , , , , Mi , , , , Batch Analysis KPI- Monitoring Process Flow Charts PIMS Trend View (out of the box) Pattern Detection Asset Monitoring 13

14 PIMS Data Analysis Pattern Recognition in PIMS Data Motivation 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 Features Easy selection of all relevant tags Easy selection of reference range Automatic pattern search and result visualisation Configuration of match tolerance Benefits 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 14

15 Batch Analysis Batch Runtime Monitoring and Analysis Unit Procedure level Operation level Phase level Analyze performance of different units Analyze performance of different operations (of a unit) Analyze performance of different phases (of an operation) 15

16 Manufacturing KPI Monitoring Output?? Cost?? What are the current production cost? How did the new control strategy influence the energy cost? When did I lastly gain a higher output? Output Cost per t of product Monthly report Production amount: 700 t Material cost: 234 /t Energy cost: 67 /t Manufacturing KPI Monitoring 16

17 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 KPI - Cockpit 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 17

18 MES-Infrastructure and Operational Intelligence Full transparency on all data sources Standardized integration of data sources KPI-Cockpit Standard MES Applications SHR Asset Effectiveness Shared information bus with context model (MES-Bus) Tag Explorer Calculations Intranet Standardized MES Applications Trender Visual Tile Composer Intranet Links MES-Infrastructure platform MES-BUS Standard Functionality Visualization Library BDIS Aspen IP.21 / Osisoft PI > 160 PIMS AE > 2000 Assets AM > 150 plants CPM > 150 plants SGU > 150 plants SAP > 150 plants KVP ELP LIMS > 150 plants > 150 plants > 60 LIMS 18

19 Simplified Generic MES Landscape Serves as Template for Tailoring Vertical Integration Solution Manufacturing Operations Management Application Manufacturing Intelligence Solution PIMS Horiz. Integration LIMS 19

20 BASF SE at a glance MES as Key for Operational Excellence Best Practice MES in Process Industry Summary & Outlook 20

21 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. From Data to Information! Outlook Trend towards multi-plant and multi-site MES Standardization and consolidation of MES landscape and interfaces for improved interoperability 21

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23 Data collection processing aggregation Automate Monitor Plan BASFs Automation Pyramid Information flow Strategic planning and transaction of business processes Enterprise Ressource Planning (ERP), Business IT, SAP/R3 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) ERP MES APC [d] [h] [min] 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 Physical process material flow, enregy flow DCS, SPLC Instrumentation Plant [s] 23