Reaching across boundaries, collaboration, Web Parts, and Notifications

1 Empowering Business in Real Time. © Copyright 2009, OSIsoft Inc. All rights Reserved.

Reaching across boundaries, collaboration,

Web Parts, and Notifications

Jim Cummins

Manager: Process Information


“Specialty Minerals has a very dispersed work force with small facilities located around the world. Consolidating and surfacing production information is essential for daily management. Web Parts is a tool that integrates well with our web based communications. “

Customer Business Challenge

Solution Customer Results / Benefits

SMI: Sharing Information World Wide

• Collect accurate process information from small facilities located globally.

• Provide a single source for viewing many locations and processes to employees in non centralized locations.

• Communicate requirements to suppliers for automated deliveries.

• Implemented a single PI server with interfaces to manufacturing facilities world wide.

• Implemented MS SharePoint with PI web parts to expose process information.

• Implemented notifications tied to inventory to Email suppliers.

• Dashboards and process analysis are driving continuous improvement ; lowering product costs improving performance.

• Integration of information from multiple data sources.

• Timely, reliable, communication for material suppliers.


Specialty Minerals

Synthetic Calcium Carbonate

Facilities: 53 located globally

Employees: 3 to 15 per location

Symbiotic relationship with paper mill

Paper Machine

Paper MillLime

Source

Chemical

Sources

Local

Labor

MTI Proprietary Technology

Gas

H20

Waste

Power

PCC

Plant

PCC Slurry


Facility Design

• Facilities are highly automated using Siemens PCS7 DCS systems.

• Plants are or can be operated by a single individual or in many cases unmanned for periods of time.

• Plants will run continuously 24X7 as needed to meet mill demand.

• Product is delivered to host mill by pipe line.

• Off site customers are supported with truck deliveries.


Our History with OSIsoft

• PI server was installed in Easton PA. data center in 2007. Data interfaces were installed at 8 facilities replacing local data Historians.

• Additional facilities were added in 2007 and 2008 including locations in Europe, Africa, South America, and Asia. PI ACE was added to populate batch tables in SQL Server.

• MS SharePoint Server was deployed with PI Web parts to expose process data on the secure company network.

• PI to PI interface has been used to link directly with the customer.

• PI Notifications has been used to communicate inventory levels to raw material suppliers.


Interface and data collections

• Each of the facilities use a PI OPC interface installed on the Siemens PCS7 process control system operator interface computer.

• Process data is continuously streamed to the central server. Data is buffered at the plant in the event of a connectivity loss.

• PI Batch and PI ACE are used to create batch records in SQL Server.


Challenge

Business processes needed to be stream lined.

Data quality, Timeliness, Labor, results distribution.


Challenge: Time to collect and Quality

of dataCollecting information from each plant required many forms and manual

data collection


ChallengeData consolidation and Analysis


Challengedata storage, access, and

reporting


Challenge


Data quality, Timeliness, Labor, results distribution.


Solution


Data quality, Timeliness, Labor, and Reporting .


The Solution: Data Collection

• Install PI Server in Easton PA with interface to all facilities.

• Collect process data for each plant using PI OPC Interface

• Implement PIBaGen (PI Batch Generator)

• Utilize PI Process Book and Data Link

One Source for process informationOne version of the truth


The Solution: Consolidation

• Collect process data for each plant on one server.

• Implement ACE to create Batch Records in SQL Server.

• Plant information Roll up capabilities

One Source for process information.One version of the truth.


The Solution: Reporting

• Expose summary information using MS SharePoint

• PI Web Parts for quick summary of process information

• PI Notifications for supplier communication

One Source for process information.One version of the truth.


Solution


Data quality, Timeliness, Labor, and Reporting .

Connection to each facility

SIMATIC S7

Local Programming

Production network

HMI

MTI Firewall

Plant Firewall

PI Historian and web server

End user tools

PI WebParts

OPC Interface

Typical Plant Configuration

Office network

CollaborationCollaborationContenConten

t t ManagManagementement

Electronic

Forms

Intranet / Intranet / ExtranetExtranet

Search

Business Business IntelligenceIntelligence

MOSSMOSS

“Extensible Server design”Initial Setup

Growth

Company Wide Implementation

Controlling costExpansion capability over time without

losing past investment


Significant steps to implementation1. Initial deployment of PI

a. Install and manage PI server.

b. Install and manage interface on each

control system.

c. Use PI client tools including data link and

process book to involve end users. Show

immediate benefits in data acquisition and

analysis.

d. Listen for suggestions to improve analysis.


Significant steps to implementation2. Add more value over time with

each new application.

a. Install and manage PI Batch.

b. Install and manage PI ACE.

c. Install SQL Server.

d. Configure your batch triggers and create

batch records from continuous data.

e. Involve end users. Show immediate

benefits in data acquisition and analysis.


Significant steps to implementation3. Add value with each new

application

a. Install and manage MS SharePoint .

b. Install PI Web Parts and Baseline.

c. Create and publish batch summaries using tree

view, table views, Time, and batch view.

d. Create pages to show plant KPIs, production,

and other related information.

e. Involve end users.


Significant steps to Benefits

4. Listen to end users and get them involved.

a. Develop actionable web pages from web parts

to support internal company operations,

management, and reporting requirements.

b. Improve your relationship with customers by

implementing a PI to PI interface to their PI

system.

c. Communicate to suppliers using PI

Notifications.


Benefits

One source of the truth + Improved accuracy + Faster recognition of opportunities + Informed decisions = Lower costs


Benefits

• Reduced time to collect and collate data

• Removes one roadblock to unmanned operation

• Accurate and verifiable data

• Removes one roadblock to unmanned operation

• One source for process data

• Every one works off the same data source

• Reduction in time spent validating information

• One version of the truth


Benefits

• Process metrics including OEE calculations

• Data to measure KPIs

• Real time access to information from anywhere

• Export from web site to Excel for unique analysis using third party modeling software.

Supporting the Continuous Improvement Process

Collect Data

Identify Opportunity

Analysis

Solution

Feedback

With WebParts

CollaborationCollaborationContent Content ManageManage

mentment

Electronic Forms

Intranet / Intranet / ExtranetExtranet

Search

Business Business IntelligenceIntelligence

MOSSMOSS

PI Web Parts


Current Challenges

• Migration from SharePoint 2003 to SharePoint 2007

• Building content at the rate it is requested.


“Specialty Minerals has a very dispersed work force with small facilities located around the world. Consolidating and surfacing production information is essential for daily management. Web Parts is a tool that integrates well with our web based communications. “

Customer Business Challenge

Solution Customer Results / Benefits

SMI: Sharing Information World Wide

• Collect accurate process information from small facilities located globally.

• Provide a single source for viewing many locations and processes to employees in non centralized locations.

• Communicate requirements to suppliers for automated deliveries.

• Implemented a single PI server with interfaces to manufacturing facilities world wide.

• Implemented MS SharePoint with PI web parts to expose process information.

• Implemented notifications tied to inventory to Email suppliers.

• Dashboards and process analysis are driving continuous improvement ; lowering product costs improving performance.

• Integration of information from multiple data sources.

• Timely, reliable, communication for material suppliers.


Jim CumminsManager: Process InformationSpecialty Minerals [email protected]

Documents

Reaching across boundaries, collaboration, Web Parts, and Notifications