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© Copyr i gh t 2013 OSIso f t , LLC.
Deployment of
the PDH
Infrastructure at
Verallia
Pedro Baptista, Project Manager
Vincent Turck, Industrial IT Director
© Copyr i gh t 2013 OSIso f t , LLC.
2nd leading international glass manufacturer in 2012
– 3.8 billion in sales
– Approximately 25 billion bottles and jars produced in 2012
– Industrial presence in 14 countries, with 58 sites (46 glassmaking production sites), 10 technical centers and 94 furnaces
– More than 14,000 employees around the world
– Commercial presence in 46 countries with over 10,000 customers
– 13 innovation awards in 2012
A worldwide leader attentive to its
customers
2
© Copyr i gh t 2013 OSIso f t , LLC.
2012 Sales:
3.8 billion Euros
3
In millions € 2012 2011
Sales (*) 3,792 3,628
Operating Income (*) 414 448
EBITDA (*) 656 685
Capital Expenditure (*) 285 272
Still wines
29%
Sparkling wines
9% Spirits
10%
Food
18%
Other bottles
9%
Other (including
tableware and decoration)
4%
Beer
21%
By End Market
Western Europe
56% Eastern Europe
3%
South America
8%
United States
33%
By Geographical Area
© Copyr i gh t 2013 OSIso f t , LLC. 4
A worldwide industrial and commercial presence, aligned
with the markets (*)
4
Industrial presence in 13 countries Commercial presence in 45 countries 44 industrial sites
(*) excluding Verallia North America
© Copyr i gh t 2013 OSIso f t , LLC.
PDH Project : Process Data Historian
PDH is an Infrastructure to collect, store and publish raw data directly from the field. PDH uses the PI System from OSIsoft.
PDH is a global system and PI Server & PI AF Server are installed in a central Datacenter.
Business Applications will be developed on top of this PDH Infrastructure.
5 5
© Copyr i gh t 2013 OSIso f t , LLC.
PDH : Data Flow
6
© Copyr i gh t 2013 OSIso f t , LLC.
PDH : Central Architecture
7
© Copyr i gh t 2013 OSIso f t , LLC.
PDH Pilot : Compressor & IS Air Application • Objectives
– Control the Compressed Air production and consumption.
– Analyze data to find the optimize process.
• Benefits Reduce Cost
8
© Copyr i gh t 2013 OSIso f t , LLC.
– 39 Sensors to measure flow, pressure, temperature
• All compressors
• Furnace
• Cold End
• 2 Machines (2x Tandem)
– Every half machine equipped separately
– Measurement devices for Power.
– Measurement devices for Hydrometric point
9
PDH Pilot : Compressor & IS Air Application Scope
© Copyr i gh t 2013 OSIso f t , LLC.
Architecture of PDH compressed air solution
10
© Copyr i gh t 2013 OSIso f t , LLC.
Compressed Air deployment : Feedbacks
11
Some IS machines consume three times more air than others.
Some systems consume more air than theorical model.
Compressor Control Command was setup with wrong parameters.
Operators were not following industrial rules and were wasting air during job changes.
© Copyr i gh t 2013 OSIso f t , LLC.
PDH : choosing our optimal clients tools V1 Data are accessible via PI AF only in order to use “Element Relative Display”
One Single PI ProcessBook for Operators.
Heavy VB development in PI ProcessBook (mainly to switch from one plant to another) : Slow response time.
One Single PI ProcessBook not relevant for our central architecture.
One Excel PI DataLink file for client reporting
Excel is slow mainly due to PI AF browsing.
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© Copyr i gh t 2013 OSIso f t , LLC. 13
Common element
structure for all
countries & plants.
Standard Attributes
Naming
Last Level is
specific to each
plant
PDH : choosing our optimal clients tools V1
© Copyr i gh t 2013 OSIso f t , LLC. 14
PDH : choosing our optimal clients tools V1
© Copyr i gh t 2013 OSIso f t , LLC. 15
PDH : choosing our optimal clients tools V1
© Copyr i gh t 2013 OSIso f t , LLC.
Data are accessible via PI AF only in order to use “element relative display”
One PI ProcessBook per Plant for Client Operators
PI ProcessBook is much faster. Easy to develop.
Multiple PI ProcessBook files to manage and update.
SAP BusinessObjects with PI OLEDB for reporting
PI OLEDB difficult to implement. TechSupport was involved to help.
One common and global reporting tool.
Merging SAP Data is also possible.
PDH : choosing our optimal clients tools V2
16
© Copyr i gh t 2013 OSIso f t , LLC. 17
PDH : choosing our optimal clients tools V2
© Copyr i gh t 2013 OSIso f t , LLC. 18
PDH : choosing our optimal clients tools V2
© Copyr i gh t 2013 OSIso f t , LLC.
Data are accessible via PI AF only in order to use “element relative display”
One home made web application based on PI AF SDK for all operators.
Web Based Application
Fast access to different plant organization
Automatic screen setup mapped on PI AF model structure.
Very Easy to update.
Home made application more difficult to maintain.
SAP BusinessObjects with PI OLEDB for reporting
PI OLEDB difficult to implement.
One common and global reporting tool.
Merging SAP Data is also possible.
PDH : choosing our optimal clients tools NEXT
19
© Copyr i gh t 2013 OSIso f t , LLC. 20
PDH : choosing our optimal clients tools NEXT
© Copyr i gh t 2013 OSIso f t , LLC.
PI
& A
F
Se
rve
r
PI
Inte
rfac
e
Se
rve
r Verallia
Industrial IT
Local
Industrial IT
Local
Project Manager
Shop floor
operator
Administration
Configuration
Standardization
TAG & Structure
Creation
TAG Definition
Nothing
Standardization
Support Nothing
Administration
Configuration
Se
cto
r
Ap
plic
ati
on
s
Support
Creation
Deploy
Manage
Lo
ca
l
Ap
pli
ca
tio
ns
Nothing
Nothing
Specifications
Testing
Training
Use
Use
Creation
Deploy
Manage
Support
Specifications
Testing
Training
PDH : Team Roles
21
© Copyr i gh t 2013 OSIso f t , LLC.
PDH : Summary, our Client Strategy for now
Local Applications : PI ProcessBook
Specific Reports : PI DataLink
Global Applications : Web Application (home made)
Global Reports : SAP BO
22
© Copyr i gh t 2013 OSIso f t , LLC.
Contacts
Pedro Baptista
Project Manager
Verallia
Vincent Turck
Industrial IT Director
Verallia
23
© Copyr i gh t 2013 OSIso f t , LLC.
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24
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