Implementing Plant Information Management Systems … · ERP Process Controls ... Reporting...

© Copyr i gh t 2014- 15 O SIs o f t , LLC .

Presented by

Implementing Plant Information

Management Systems (PIMS)

Strategies For Success

OSIsoft

AG

EN

DA

Agenda

A discussion on why PIMS/MES projects fail, followed by the presentation of an alternative approach to implementation that should, if properly engaged, eradicate the two largest causes of failure.

A DISCUSSION ON FAILURE

“ I have not failed. I’ve found 10,000 ways that

won’t work.”

Thomas Edison

In our Experience…

200+ MES implementations in the

last 10 years.(we’ve learned a few things)

PIM

S / M

ES

FA

ILU

RE

S

We think that it really boils down to these two things:

1.Infrastructure / Architecture

2.Requirements Definition

FA

ILU

RE

MO

DE

SA

NA

LY

SIS

Lack of Support IN

DIC

AT

ION

ST

HA

TF

AIL

UR

EM

AY

BE

IMM

INE

NT

“We’re kind of doing this project under the radar.”

Lack of Real Funding IN

DIC

AT

ION

ST

HA

TF

AIL

UR

EM

AY

BE

IMM

INE

NT

“We’re going to fund this from the maintenance

budget and see where it goes…”

Lack of Departmental Cohesiveness IN

DIC

AT

ION

ST

HA

TF

AIL

UR

EM

AY

BE

IMM

INE

NT

“We have to keep IT out of this…”

“Yeah, I know. They’re so paranoid.”

Inability to Learn from Past Mistakes IN

DIC

AT

ION

ST

HA

TF

AIL

UR

EM

AY

BE

IMM

INE

NT

“You know, the stuff that those other guys

put in was really crappy.”

“I think this time we’ll start by just putting

some data into MySQL.”

PIMS A N D MES – MAKING THE CASE FOR INFRASTRUCTURE

“The significant problems that we face cannot be solved at

the same level of thinking we were at when we created

them.”

Albert Einstein

Custom DB

Custom Data Connector

Scheduling

OEE

LIMS

The Progression of Manufacturing Software - Historically MA

NU

FA

CT

UR

ING

SO

FT

WA

RE

Reliability Operations Quality

Historian

ERP

Process Controls

OEE Configuration

OEE Reporting Quality Reporting

Historical Trends

Data Analysis

Operational Reporting

Financial/Transactional Reporting

Custom Report

OEE

OperationsLIMS

Building From a Solid Base – PI System Infrastructure MA

NU

FA

CT

UR

ING

SO

FT

WA

RE

PI Archive

ERP

Process Controls

Transactional Reporting

PI Interfaces

Asset Framework

Data AccessPI Visualization

Event Frames Notifications Analytics

Historical Trends

Data Analysis

Custom Reporting

Quality Reporting

OEE Reporting

OEE

Scheduling

LIMS

Asset Framework as the Centerpiece of PIMS AS

SE

T-B

AS

ED

PIM

S

PI Archive

ERP

Process Controls

PI V

isualizatio

n / P

I Data A

ccess

Asset Framework

Event Frame

Notification

OEE

Scheduling

LIMS

Asset Anatomy AS

SE

T-B

AS

ED

PIM

S

PI Archive

ERP

Process Controls

PI P

rocess B

oo

k (Elemen

t Relative)

Processing Vessel #1

Test Values

Current Lot #

Current State

Raw Material Data

Process Values

Reliability Records

Batch Records

Process Excursions

PI D

ataLink / M

S Pow

er BI

PI C

oresigh

t

PI D

ata Access

A REQUIREMENT IS A REQUIREMENT. RIGHT?

“ You got to be careful if you don’t know where you’re

going because you might not get there.

‘Yogi’ Berra

The Business Model DE

FIN

ING

RE

QU

IRE

ME

NT

SBusiness Model

Business Rule

Business Requirement(s)

Fulfills

The System Model DE

FIN

ING

RE

QU

IRE

ME

NT

SSystem Model

User Requirement (s)

Functional Requirement(s)

Fulfills

The Language Barrier DE

FIN

ING

RE

QU

IRE

ME

NT

SBusiness Model

System Model

Asset

SETTING THE STAGE FOR SUCCESS – TOP DOWN DESIGN

“ Obstacles are those frightful things that you see when

you take your eye off of the goal.”

Henry Ford

Fulfillment of the Business Rule BU

ILD

ING

RE

QU

IRE

ME

NT

S

BUILDING ON SUCCESS: ITERATIVE DEVELOPMENT

“Each problem that I solved became a rule which

served afterward to solve other problems.”

Rene Descartes

Develop Requirements

Implement Assets

Validate Deliverables

Prove ROI

CY

CL

IC, R

OI-D

RIV

EN

DE

VE

LO

PM

EN

TO

FP

IMS

Prioritized List by Projected Return On Investment

CO

NT

AC

TI

NF

OR

MA

TIO

N

Kirt Anderson

• kanderson@stonetek.com

• Sr. MES Project Manager

• Stone Technologies, Inc.

© Copyr i gh t 2014- 15 O SIs o f t , LLC .

Brought to you by

© Copyr i gh t 2014- 15 O SIs o f t , LLC .27

Agenda

07:30 - 08:30 a.m. Registration and Continental Breakfast

08:30 – 09:00 a.m. Welcome: Industry Trends & Manufacturing Operational Excellence - OSIsoft Jason Kurdziel, Account Manager

09:00 - 09:30 a.m. The Journey to Real Time Operational Intelligence - OSIsoft Marc Gallant, Regional Manager

09:30 - 10:15 a.m. Journey to Asset-Based Data – The Kellogg Story John Gothberg, IT & Control Systems Manager

10:15 - 10:30 a.m. Break / Demo Pods

10:30 - 11:15 a.m. Integrating your Plant Information Management System: Strategies for Success Kirt Anderson, Senior MES Project Manager – Stone Technologies

11:15 - 12:00 p.m. Rapid Insights with Data Analytics - Tate & Lyle Mark Massey, Process Control Software Manager: Global Manufacturing

12:00 - 01:30 p.m. Lunch / Demo Prods

01:30 – 02:15 p.m. Analyzing Location for the Most Profitable Supply Chain – Esri Ryan Schacht, Account Executive

02:15 – 03:00 p.m. Chocolate PI - The Hershey Company Russell Gregg, Sr. Project Manager: IS Global Supply Chain/Manufacturing Systems

03:00 – 03:45 p.m. Evolution of OSIsoft PI to an Enterprise Agreement - Abbott Nutrition Rich Colvin, Area IT Manager: ANSC Asia & Ireland

03:45 - 04:15 p.m. Roundtable Review

04:15 - 04:30 p.m. Wrap-up/Seminar Conclusion – Jason Kurdziel, Account Manager, OSIsoft

04:30 - 06:00 p.m. Networking Reception / Demo Pods