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Empowering Business in Real Time. © Copyright 2010, OSIsoft LLC All rights Reserved.
Overcoming Logistical Challenges with Collaborative Technologies
OSIsoft Regional Seminar
San Jose, Costa Rica
Curt Hertler OSIsoft, [email protected]
June 29, 2010
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2 Empowering Business in Real Time. © Copyright 2010, OSIsoft LLC All rights Reserved.
• Traditionally, computerized systems have been focused on automating calculations, operations, and work flow processes.
• Automation is an effort to minimize the use of existing human resources.
• Emerging computer technologies are focused on access to integrated information, anywhere. Technologies like web-based portals, virtual presence, and business intelligence tools enable collaboration, allowing organizations to address challenges in new ways.
• Collaboration is an effort to maximize the use of existing human resources.
• Real-time information is essential to fuel the collaborative engine by enabling awareness and supporting continuous improvement efforts.
• Distinctive companies extending the value of their existing information systems by elevating them to provide a real-time information infrastructure for articulating objectives transparently and delivering opportunity throughout the enterprise.
Overcoming Logistical Challenges withCollaborative Technologies
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3 Empowering Business in Real Time. © Copyright 2010, OSIsoft LLC All rights Reserved.
• Enabling Awareness: The Value of Real–Time
• Delivering Opportunity: The Need for Infrastructure
• Overcoming the Challenge: Performance Intelligence
• Collaborating to Improve: The Real-Time Infrastructure in Action
Overview
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© Copyright 2010, OSIsoft LLC All rights Reserved. 4 Empowering Business in Real Time.
Enabling Awareness The Value of Real-Time
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5 Empowering Business in Real Time. © Copyright 2010, OSIsoft LLC All rights Reserved.
Assessment of Condition
Electrocardiogram
• Statement of “goodness”• Actionable• Critical
The Value of Real Time
Forecast
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6 Empowering Business in Real Time. © Copyright 2010, OSIsoft LLC All rights Reserved.
Creation of OpportunityOnline Financial Market Price Quotations
• Accessible• Responsive• Tactical
The Value of Real Time
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7 Empowering Business in Real Time. © Copyright 2010, OSIsoft LLC All rights Reserved.
The Value of Real Time
Evidence of ChangeClimate Change Data
• Convincing• Intuitive• Impactful
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8 Empowering Business in Real Time. © Copyright 2010, OSIsoft LLC All rights Reserved.
Fuel flow spikes discovered costing $93,000 / year.
Wasted Fuel Gas
The Value of Real Time
Fundamental Principle
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9 Empowering Business in Real Time. © Copyright 2010, OSIsoft LLC All rights Reserved.
TARGET FUEL FLOW
Another Opportunity – Continuous Improvement
The Value of Real Time
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10 Empowering Business in Real Time. © Copyright 2010, OSIsoft LLC All rights Reserved.
Capturing opportunities requires the right people.
The Challenge of Real Time
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© Copyright 2010, OSIsoft LLC All rights Reserved. 11 Empowering Business in Real Time.
Delivering Opportunity The Need for Infrastructure
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12 Empowering Business in Real Time. © Copyright 2010, OSIsoft LLC All rights Reserved.
Infrastructure: Characteristics and Expectations
• Valuable – delivers a recognized benefit
• Reliable and Secure – always available, safe and trusted
• Accessible – adaptable to innovation, easy to use
• Contextual - organized to be effective, efficient, and extendable
• Sustainable – must be able to last and adapt to change
Real-Time Infrastructure Delivers OpportunitiesElectrical Power
Transportation
Communications
Music
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13 Empowering Business in Real Time. © Copyright 2010, OSIsoft LLC All rights Reserved.
Reliable and Secure Architecture
Secondary
PI Server
Secondary
PI Server Primary
PI Server
Primary
PI Server
Configuration
Changes
Failover
Mechanisms
Secondary
PI Server(s)
Configuration
Changes
Clients: ProcessBook, DataLink, BatchView, RtWebParts,Custom Application…
System Management Tools AppServers: AF, RtBLS, RtReports, ACE
PI SDKDiscovery, Failover, Failback, Load Distribution Services
API BufferingServices
PI Interfaces
API BufferingServices
PI Interfaces
APIBuffering
PI Collective
Full redundancy with Microsoft Security Model.
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14 Empowering Business in Real Time. © Copyright 2010, OSIsoft LLC All rights Reserved.
Accessible by Expected Standards
• Interfacing with over 400 different automation sources
• Compliance with Industry Standards – OPC UA, PRODML, XML
• Query-based Access, OLEDB
• Integration with Microsoft Office Tools – Excel, VBA
• Integration with Microsoft and SAP Web Prortals
• Supports Application Development- OSIsoft vCampus
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15 Empowering Business in Real Time. © Copyright 2010, OSIsoft LLC All rights Reserved.
Process ContextGraphics
Analytical ContextSpreadsheets and Reports
Performance ContextProcess Calculations
Accessible by Users
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16 Empowering Business in Real Time. © Copyright 2010, OSIsoft LLC All rights Reserved.
Contextual by Asset for Efficient Extension
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17 Empowering Business in Real Time. © Copyright 2010, OSIsoft LLC All rights Reserved.
Asset Context
Relational DataReal Time Data
Formulas User Defined
Asset elements derived from a common template for each
equipment type
Contextual for Information Integration
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18 Empowering Business in Real Time. © Copyright 2010, OSIsoft LLC All rights Reserved.
Contextual for Users and Applications
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© Copyright 2010, OSIsoft LLC All rights Reserved. 19 Empowering Business in Real Time.
Overcoming the Challenge Performance Intelligence
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20 Empowering Business in Real Time. © Copyright 2010, OSIsoft LLC All rights Reserved.
Benchmarking Performance Against Objectives
Articulation of Performance Rules
Accountability of Manufacturing Objectives
Collaboration Driven by Transparent Accountability
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21 Empowering Business in Real Time. © Copyright 2010, OSIsoft LLC All rights Reserved.
Organizational Presentation of Real-time Opportunities
PI WebParts 2010 for Microsoft SharePoint 2007 or SAP Enterprise Portal
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22 Empowering Business in Real Time. © Copyright 2010, OSIsoft LLC All rights Reserved.
Email with links relevantinformation
Integration with Virtual Prescience Technology
Event-based Notification of Real-time Opportunities
PI Notifications (PI System 2010)
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23 Empowering Business in Real Time. © Copyright 2010, OSIsoft LLC All rights Reserved.
Democratized Business Intelligence
Delivered through a familiar environment
Integrated into business productivity infrastructure
Built on a trusted and extensible platform
Improving organizations by
providing business insights to
all employees leading to better,
faster, and more
relevant decisions
Microsoft BI Vision and Strategy
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24 Empowering Business in Real Time. © Copyright 2010, OSIsoft LLC All rights Reserved.
• Enable users to perform self-service analysis and intuitively build their own BI solutions
• Allow users to interactively explore and perform calculations on large data sets
• Integrate data from multiple sources
• Minimize dependence on IT support
Introducing PowerPivot for Excel
Empowering the End User
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25 Empowering Business in Real Time. © Copyright 2010, OSIsoft LLC All rights Reserved.
New Performance Intelligence Tools
Microsoft Excel 2010 with PowerPivot for Data Cube Analysis
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26 Empowering Business in Real Time. © Copyright 2010, OSIsoft LLC All rights Reserved.
• Dimensions and Facts• PI Asset Framework (PI System 2010)
• Datasets for BI Data Extraction• PI OLEDB Enterprise 2010 (PI for Office 2010)
• Desktop Analysis and Cube Configuration• Microsoft PowerPivot for Excel 2010
• Enterprise Accountability• Microsoft PowerPivot for SharePoint 2010
• Microsoft SharePoint 2010
• Microsoft SQL Server 2008 R2
• Microsoft Office Communication Server 2007 R2
• PI Notifications (PI System 2010)
Self-service BI Toolkit for the PI System
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© Copyright 2010, OSIsoft LLC All rights Reserved. 27 Empowering Business in Real Time.
Collaborating to Improve The Real-Time Infrastructure in Action
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28 Empowering Business in Real Time. © Copyright 2010, OSIsoft LLC All rights Reserved.
Enterprise Integration of Operational Data from
Wind Farms
John Mostek, O&M EngineerJohn Deere Renewables
OSIsoft 2010 User’s Conference
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29 Value now. Value over time. © Copyright 2010, OSIsoft LLC All rights Reserved.
Operating Commissioning Construction Operations Center
Project Locations
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30 Value now. Value over time. © Copyright 2010, OSIsoft LLC All rights Reserved.
Enterprise Management System
PI is the foundation on which our EMS is built, and is the basis for dashboards monitored in our Operations Center
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31 Value now. Value over time. © Copyright 2010, OSIsoft LLC All rights Reserved.
Aggregation controls(AF / MDB hierarchy)
Time controls
Dashboards
SharePoint portal environment on intranet, using PI WebParts
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32 Value now. Value over time. © Copyright 2010, OSIsoft LLC All rights Reserved.
Real-time Status Displays
PI ProcessBook rich client application
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33 Value now. Value over time. © Copyright 2010, OSIsoft LLC All rights Reserved.
Geospatial Context
Customized code to overlay real-time PI data in the Google Earth environment
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34 Value now. Value over time. © Copyright 2010, OSIsoft LLC All rights Reserved.
Production Forecasting
Web services with PI data queries, served up in Business Objects using Flash
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35 Value now. Value over time. © Copyright 2010, OSIsoft LLC All rights Reserved.
Alarms and Notifications
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36 Value now. Value over time. © Copyright 2010, OSIsoft LLC All rights Reserved.
Benefits
• 77% improvement across our fleet in Energy Capture performance metric within first 6 months of PI roll-out
• Top-line impact of Operational Awareness• Data fit within a consistent Enterprise platform• Use of templates / AF hierarchy structure = rapid
integration of new project sites• Leverages existing sources of Metadata • Extensive library of off-the-shelf interfaces
available from OSI• Future data sources become an easy fit
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37 Empowering Business in Real Time. © Copyright 2010, OSIsoft LLC All rights Reserved.
Information Driven Collaboration
Kodak
“Energy ManagementThe Infrastructure Approach”
Dr. J. Patrick Kennedy,
CEO and President, OSIsoft
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38 Value now. Value over time. © Copyright 2010, OSIsoft LLC All rights Reserved.
Information Driven CollaborationKodak Park
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39 Value now. Value over time. © Copyright 2010, OSIsoft LLC All rights Reserved.
Goals
• Reduce utility costs at Kodak Park through improved demand side management
• Consolidation of the utilities data
• Create Awareness via the Web
• Grow a Culture of Energy Efficiency
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40 Value now. Value over time. © Copyright 2010, OSIsoft LLC All rights Reserved.
Employee Portal
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41 Value now. Value over time. © Copyright 2010, OSIsoft LLC All rights Reserved.
Mini Projects• Demand Side
• Better correlation of MFG energy usage to production volumes
• Identified opportunities in manufacturing to implement an energy conservation mode between product runs
• Extended carbon recovery cycles
• More effective utilization of labs with fume hoods
• More effective “Time of Day” scheduling for lighting and HVAC
• Temperature / HVAC fan set points
• System is considered an essential tool during our energy savings workshops (Kaizens)
• Heightened awareness of many end users
• Generation Side• Plant loading optimization
• Boiler fan optimization
• Exhaust head improvements
• Better management of self generation vs. purchased power
• Improved deaerator utilization
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42 Value now. Value over time. © Copyright 2010, OSIsoft LLC All rights Reserved.
Harvest Time
• The Energy Information System (EIS) has been an essential tool to help us reach our goal of:
“One Powerhouse for Kodak Park”
(10:41:53 March 28, 2007)
• Collectively the “annual” savings rate in 2007 was $27 Million
• Today the “annual” savings has grown to more than $30 Million
• The cumulative savings is now in excess of $100 Million
- UPDATE
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43 Value now. Value over time. © Copyright 2010, OSIsoft LLC All rights Reserved.
Lessons Learned
• Continuous Improvement Process
• No BIG BANG – 1000 little bangs
• Combined Capital and Intelligence Operation
• Infrastructure Approach – Remove Infrastructure from Projects
• Lowers the Cost of Curiosity
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44 Value now. Value over time. © Copyright 2010, OSIsoft LLC All rights Reserved.
Energy Conservation Program – Continues
• Corporate Environmental Goals
• The last Goals were to Reduce Energy & GHG Emissions 20% by 2008, from a 2002 Baseline. We achieved roughly a 40% reduction in both.
• The new Goals are to Reduce Energy & GHG Emissions 50% by 2012, from the 2002 Baseline.
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45 Value now. Value over time. © Copyright 2010, OSIsoft LLC All rights Reserved.
Solution – Current status – April 2010
• Over 100,000 PI Points currently established
• 23 ProcessBook / DataLink Users
• 150 Concurrent Web Users
• 250 + iView Pages
• 30 Interfaces installed
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46 Value now. Value over time. © Copyright 2010, OSIsoft LLC All rights Reserved.
Eastman Business Park Water Reduction Initiative
• 2009 Kodak Water Reduction was 16.5%
• 1,087,000,000 Gallons (or 1,087,000 K Gallons) saved in 2009
• 1st Quarter of 2010 – an additional savings of 450 Million gallons from the 2008 Baseline
• Roughly 1.5 Billion Gallons saved in the last 15 Months
• $0.00 In Capital Spent
• These Water Savings are calculated for only the last 15 months and are totally independent of the site’s energy reductions
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47 Empowering Business in Real Time. © Copyright 2010, OSIsoft LLC All rights Reserved.
Think beyond automation. Distinctive companies are collaborating with the following
outcomes; Definition – agreed manufacturing objectives clearly
articulated, enabling contributions from all levels and areas. Accountability – gaps and best practices identified,
initiatives prioritized, progress measured and verified. Leveraged – surface and spread problems for efficient
resolution by limited experience resources. Sustainable - fundamental change in the way you work. Risk Averse - tools known, infrastructure in place. Expected – matches skill set of emerging work force. Peace of Mind – organization aligned, problems understood.
Conclusions
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Thank youCurt Hertler
© Copyright 2010 OSIsoft, LLC
777 Davis St., Suite 250 San Leandro, CA 94577