Einsatz und Nutzen von MES in der Prozessindustrie · Einsatz und Nutzen von MES in der...

Einsatz und Nutzen von MES in der

Prozessindustrie

Hisham K. Mubarak

1 22.05.2013 VDI MannheimAK Leitsysteme für die Prozess- und Fertigungsindustrie

2

BASF SE at a glance

MES as Key for Operational Excellence

Best Practice MES in Process Industry

Summary & Outlook

VDI MannheimAK Leitsysteme für die Prozess- und Fertigungsindustrie 22.05.2013

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

3

Platzhalter für Bild


BASF worldwide

Sites

4

Regional centers

Selected

production sites

Verbund sites

Most important

research sites

Freeport Geismar

São Paulo

Ludwigshafen Antwerp

Hong Kong

Kuantan Singapore

Nanjing

Florham Park


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

22.05.2013 5 VDI MannheimAK Leitsysteme für die Prozess- und Fertigungsindustrie

6

BASF SE at a glance



Summary & Outlook


Achieving Operation Excellence…

7 VDI MannheimAK Leitsysteme für die Prozess- und Fertigungsindustrie 22.05.2013

I need traceability…

I must improve

productivity…

I must improve quality …

I must reduce costs…

I must minimize

downtimes…

I need to analyze batch performance…

I need transparency …

Source: http://sites.conversionplanet.com/

Reality:

Complexity is overwhelming process

managers

22.05.2013 VDI MannheimAK Leitsysteme für die Prozess- und Fertigungsindustrie 8

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

MES Support Management und

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.


What is 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 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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11

BASF SE at a glance



Summary & Outlook


12

Plant Information System 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


http://www.scalarvis.de/Losungen/LIMS/LIMS-SV-Kurve.jpg

13

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 pattern search in

historc PIMS data

Motivation


14

BASF BatchExplorer

Batch Runtime Monitoring and Analysis

Unit Procedure level Operation level Phase level

Analyze performance of

different units

VDI MannheimAK Leitsysteme für die Prozess- und Fertigungsindustrie


different operations (of a

unit)


different phases (of an

operation)

22.05.2013

15

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


SAP (PP-PI, QM, PM, MM)

Middleware

DCS

PIMS

Filling Control

Asset Monitor Rotating Equipment

0 Warehouse Management

Middleware

Labelling

Asset Monitor Intell. Feldgeräte Alarm-

Monitor Controller- Monitor

Chromatographie Data System

LIMS

Overcoming non-standardized data

integration


Initial situation in 2010

Many non-interconnected automation systems

Heterogenous and plant specific integration solutions („Spaghetti-Integration“)

Utilities Warehouse Production Filling Lab

MES Infrastructure

Definition and Attributes

MES Infrastructure:

Defined set of systems, products and technologies that serve the provision of differentiated MES solutions.

Main attributes of an infrastructure

Openness: Can be used by all user groups in an easy and convenient way

Extensibility: Supports flexible integration of new elements to the infrastructure

Technology independence: Infrastructure independent of underlying technologies

Sustainability: Maintenance and enhancement are efficient and reliable


Shift Master Production

Manager

Asset

Manager

Laboratory

Process

Manager

Plant Manager

Batch performacne comparison

Root cause analysis Input of sample results

Collection of environmental data

Shift report

Shift hand-over Production data analysis

Production costs

KPI-Cockpit

Performance analysis KPI Cockpit

Asset Effectiveness

Centers of Expertise

User Groups and Roles


MES Infrastructure Concept


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

SAP IP21

Database

Adapter SAP

Adapter

Webservice-

Adapter

IP21-

Adapter

PLS PLS LIMS PLS PLS AMS

PLS PLS Alarm-DB

PI-

Adapter

PHD-

Adapter

PI PHD PIMS PLS PLS CPM-DB

PLS PLS PLS

ME

S-I

nfr

astr

uctu

re

(XH

Q)

Real Time Data Integration

(Access, Context, Calculations, Aggregation, Validation)

Open Interface for external Applications

External Data Sources

Tools

for

Configur-

ation

Tools

for

Visualizat

ion and

data

analysis

Standard

KPIs

Shift

Handover

report

MES-I Master Data structure (MDS)

Automatized creation and update of

contextual data model


Functional location

Automatic daily synchronization Configurable matching rules

PIMS Tags

+

Extract, Transform, Load (ETL)

http://www.erpdb.info/wp-content/uploads/2007/11/what-is-sap.gif

http://honeywell.com/

User configurable interface design


Shift Master

Plant Engineering

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-Applications and Operational Intelligence Full transparency on all data sources


> 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

Standard Application

KPI - Cockpit


KPI-Cockpit Functionality

Specific raw material consumption

Specific energy consumption

Alarm Monitoring (AM)

User defined plant specific KPIs

SHE – Safty, Health, Environment

Controller Performance

Monitoring (CPM)

Asset Effectiveness KPIs

Qualification KPIs

Continuous Improvement KPIs

Technical KPIs

KPI - Cockpit

KPI - Cockpit

Standard Application

Shift Handover Report


Shift Handover Report Functionality

Maintenance report

Shift report book

Tank overview

Z-circuit status

Process deviations

Production KPIs

Plant status

Top 20 Alarms

Top 20 Control loops

Plant status Tank overview

Selectivity Maintenance

Top 20 Alarms

Report Book

Simplified Generic MES Landscape per

Plant

25 22.05.2013

PIMS LIMS

Vertical Integration

Solution

Manufacturing Operations

Management Application

Horiz. Inte-

gration

Manufacturing Intelligence Solution

VDI MannheimAK Leitsysteme für die Prozess- und Fertigungsindustrie

26

BASF SE at a glance



Summary & Outlook


Summary and Outlook


From Data to Information!

Summary

MES Infrastructure is a key driver to harmonize and standardize BASFs MES landscape

Major benefit of MES is transparency and automation of process management tasks

Ongoing roll-out of XHQ in 3 major European sites

Outlook

Extension of roll-out scope to other sites as required

Implementation of advanced XHQ-based MES applications for batch analysis, production KPI calculation and reporting

Extension of current site-oriented structure to multi-site enterprise MES-Infrastructure

22.05.2013 28 VDI MannheimAK Leitsysteme für die Prozess- und Fertigungsindustrie

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