HOW CAN PROFICY SERVE THE ENERGY ISSUE? by Coleman Easterly Feb 2008.
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Transcript of HOW CAN PROFICY SERVE THE ENERGY ISSUE? by Coleman Easterly Feb 2008.
HOW CAN PROFICY SERVE THE ENERGY ISSUE?
by Coleman Easterly Feb 2008
How can Proficy Serve the Energy Issue?
Let’s explore:• What is Proficy? (What it does best)• What about energy in manufacturing?• What opportunities to save energy?• Which ones can Proficy serve?
What is Proficy Plant Applications?
• System for automating and integrating the information tasks of managing and optimizing manufacturing performance
Value of ProficyTM
Ranked By $
1. MOM2. ERP3. CRM4. SCM5. PM
Ranked By Driver
1. Compliance
2. Customers3. Competiti
on
• Business Process Integration• Execution Of Production Orders• Shop Floor Scheduling / Sequencing• Product Quality and Compliance• Product Traceability• Workflow Management • Performance Monitoring / OEE• Asset Maintenance
Confidential – do not distribute
$ $ $
$ $
$$
Can’t control what you can’t see…
(Proficy)(Proficy)
Can control what you can see…
Real-time SituationAwarenessFrom this To This
Historical UnderstandingFrom this To This
?
How It Works Proficy continuouslymonitors raw data… based on configurations…
detects and interprets events and collects information…
Logs data, calculates KPIs, and monitors against stds…
provides reports and analysis to help you understand why…
alerts you with alarms & emails…
What you do with Proficy
• Manage objectives• Drive Activity• Capture reality• Monitor compliance• Communicate• Capture reasons• Analyze and report• Evaluate/Evolve and improve
(Performance Management)
Proficy Strengths
• Performance Management:– Driving business objectives into manufacturing– “Actionable Intelligence” from data
• Data collection & Integration – the whole picture• Conformance tracking• Real-time Visibility• Historical Analysis• Automated Reporting
• Self-sufficient system management
WHAT ABOUT ENERGY IN MANUFACTURING?
Motivation is Increasing for Energy Conservation
• The Environment • Cost Pressure (competition for products and
fuel)• Citizenship / Company Image• Regulatory Pressure
Remember these Culture Shifts?
• Safety OSHA, TCIR, S.T.O.P., • Quality ISO 9000, 6-Sigma• Cost BPR, ABC, ERP• Productivity OEE, LeanAnd now (or simply more-so)• Energy EPA, ISO 14000, GHG, Ecomagination,
Cluster Rule, Carbon Credits…
HERE ARE SOME DETAILS OF A GOVERNMENT STUDY
Of Energy consumed for Manufacturing, only a fraction delivers useful work. Most is lost in
generation, delivery, and the process.
Energy Consumed or Wasted for Manufacturing
Useful Work
Lost in Process
Lost Before Process
Gen & Trans Loss before Site
20% of Industries use 80% of the energy
Proficy grew up in these industries – a perfect fit!
15% of all mfg energy wasted at these
WHAT OPPORTUNITIES TO IMPROVE?
Top 20 Energy Opportunities
We want to zero in on a few
Process Optimization and Best Practices is a huge component of the
opportunities
Best Practice makes a huge contribution
Key Points from Energy Roadmap
• Improve systems to convert energy to useful work more efficiently (thermal, electrical, mechanical)
• Minimize Energy and Cost, while meeting product specifications and operating requirements
• Improve productivity through reduction in product waste, optimized processes and schedules
Key Points from Energy Roadmap
• Improve systems to convert energy to useful work more efficiently (thermal, electrical, mechanical)
• Minimize Energy and Cost, while meeting product specifications and operating requirements
• Improve productivity through reduction in product waste, optimized processes and schedules
Improve the physical Mfg Processes
Improve overall effectiveness/efficiencyOptimize and Balance Priorities
HOW CAN PROFICY HELP?
Proficy can help by Ratcheting Best Practices!
• Improve systems to convert energy to useful work more efficiently (thermal, electrical, mechanical)
• Minimize Energy and Cost, while meeting product specifications and operating requirements
• Improve productivity through reduction in product waste, optimized processes and schedules
Improve the physical Mfg Processes
Optimize and Balance Priorities
Improve overall effectiveness/efficiency
What you do with Proficy
• Manage objectives• Drive Activity• Capture reality• Monitor compliance• Communicate• Capture reasons• Analyze and report• Evaluate/Evolve and improve
(Performance Management)
Examples of Proficy ImpactProficy Plant Applications is production operations
management with actionable intelligence to optimize across the priorities of manufacturing, and balance
the trade-offs between them.
Mfg Operation Operating Topic Improvement Result
Beverage PackagingSchedule & BOM
Management & ERP Synchronization
5% productivity
CPG Production Quality & Traceability Management
Traceability Compliance in
Customer Audits
Wire Production Inventory & Consumption Management
$2MM Inventory reduction
Food Packaging Efficiency Management 10% Productivity
CPG Production Run-to-Target and Process Center-lining 2 to 5% Productivity
Brewing & Packaging Energy Management 5% Mfg Cost
Reduction
Food Production Environmental Management
Compliance and performance
Details of these examples in notes view of this slide
Proficy versus Major Capital Improvement Projects
• Lower risk (less cost than capital projects)• Need data anyway, to justify and evaluate
capital projects• Need actionable information anyway, to run
them
Proficy can help conserve energy by:
• Optimizing and Balancing Priorities: Minimize Energy and Cost, while meeting product specifications and operating requirements– Track quality, process, and energy variables– Analyze correlations, performance capabilities– Calculate KPIs from mixed inputs (kW/lb, $/lb,
etc)– Evaluate Energy Improvement efforts to assure
they don’t mess up quality or something else– Capture, enforce, and ratchet best practices
Proficy can help conserve energy by:
• Improving overall efficiency: Improve productivity through reduction in product waste, optimized processes and schedules– Track OEE (Availability * Throughput * Quality
Yield)– Center-lining ratcheting (sustained) best
practices– Support Lean and 6Sigma approaches
Target
USLLSL
CenterProcess
ReduceSpread
Defects
Six Sigma: The Philosophy Reduce variation & center the
processOff Target Excessive Variation
Target
USLLSL
Target
USLLSL
. . . Any Process or Value Stream
After
Before
Wait / Waste . . .Non Value Add TimeWait / Waste . . .Non Value Add Time
Lean Attacks Waste Here
Work . . . Value Add Time Work . . . Value Add Time
Lead Time / Cycle Time
•Reduced Cycles•Better Delivery•More Capacity•Better Quality•Productivity
Improved CustomerSatisfaction
Lean: The Philosophy Expose and reduce waste
Where is Waste in Manufacturing? These not only waste time and
money, but also ENERGY
Overproduction
Inventory
Extra Processing
Motion
Defects
Waiting
Transportation
• Processing before next operation is ready• Processing prior to need• Making decisions too early
• Multiple credit applications awaiting approval• Unnecessary document / data storage
• Navigating multiple screens to input data• Multiple ways to do the same task• Printed material• Duplicate entries
• Navigating multiple screens to input data• Printing Material• Ergo…walking, bending, twisting• Looking for data / info
• Personal data incorrect• Missed customer due dates• Data entry errors• Rework
• Credit applications awaiting approval• Info awaiting an overnight “systems batch run”• Manual decisions• System downtime / response time
• Delivering hard-copies• Shipping hard-copies requiring signature
• Sub assemblies and components between feeder & main lines
• Material between operations & process steps• Inventory stored in warehouses• Buffer & safety stock inventory
• Planned re-work• Un planned re-work• Handwork…polishing, deburring
• Operators bending, turning, twisting, reaching, walking• Machines “cutting air”• Robotic motion “getting back to home”
• Poor quality of materials• Equipment failures• Missing customer due dates…internal & external
• Operators waiting• Machines waiting • Customers waiting
• Conveyance of any materials, tooling• Conveyance systems
Lean
Drives Cycle Time Reduction Leveraging Proven Solutions
… Maximizes Customer Responsiveness With the Least Inventory/Resources
Lean Six Sigma = Efficiency & Consistency
Six Sigma
Drives Defect Reduction Leveraging Analytical Techniques
… For Complex Problems with Unclear Root Causes or Design Solutions
TimeAfter
Before
TimeValue addedNon-Value added
Proficy Helps You To:
• Save Energy• “Do the Right Things Right”• Automate Information Tasks (logging and
reporting)• Prioritize and Focus Improvement Effort• Evaluate Performance• Evolve Self-Sufficiently