The Secret Ingredient in Operational Data and Technology · digital transformation journey? A....

© Copyright 2019 OSIsoft, LLC 2

The Secret Ingredient in Operational Data and Technology

Kevin GenevaSenior Technical Advisor, OSIsoft

© Copyright 2019 OSIsoft, LLC

Kevin Geneva• OSIsoft since 2011 in Philadelphia, PA• Mechanical Engineering from Penn State University• Technical Support, Field Service, PreSales Support,

and Product Management

© Copyright 2019 OSIsoft, LLC© Copyright 2019 OSIsoft, LLC

Polling Question 1…Where is your company in their

digital transformation journey?A. Considering options, but have not started

B. Don’t know, unsure

C. Fully on board, have processes in place for the journey

D. Have a pilot in place, evaluating

E. Have an ongoing successful project in place, and looking to do more

F. Nowhere, done nothing


Polling Question 1…Where is your company in their

digital transformation journey?

11%

11%

44%

11%

22%

Considering options,but have not started

Don't know, unsure

Fully on board, haveprocesses in place forthe journey

Have a pilot in place,evaluating


1250 Registered Attendees98 Customer Presentations24 Partner BoothsDay 2 – Industry Day

Food and Beverage StatusAvebe – Transformation to a data-driven organizationActemium – Mobile App powered by NFC and the OSIsoft PI SystemLonza’s PIVOT – Productivity Improvements via Operations Technology


In the Pressure Cooker

9

Margin Pressure

Changing Consumer Demands

Product Quality and Food Safety

Cost of Capital


Maintenance means more to Food and Beverage

10


Point Solution < Data Infrastructure

12


How can a data infrastructure solve this?

13

Quality System Integration with

Notifications

Edge Data Collection for

Vibration

OEE – Bad Actors Report

Condition-Based Maintenance


Empower People to Drive Results

We believe that

people with data will

transform their world

Transform data into decision ready information


Polling Question 2…What are the business problems that you

are looking to address with operational data technology?

A. Process Productivity

B. Quality/Safety

C. Energy Efficiency

D. Asset Health


Polling Question 2…What are the business problems that you

are looking to address with operational data technology?

42%

0%

33%

25%

Process Productivity

Quality/Safety

Energy Efficiency

Asset Health


• - Chemical Engineering Background

• - Since August 2018 @ MIT

• - Application contact / Adminfor the PI System & TrendMiner

Manager Manufacturing IT

Jan Spijkerman

Engineer Manufacturing IT

Justin Lambeck


www.avebe.com


We extract everything to be had

19


Market - Food Ingredient Solanic

• Potato protein• Vegetable proteins• Non-allergenic, free of GM

materials, clean label, gluten-free• Very high nutritional value• Vegetarian, vegan, kosher & halal,

sustainable

20


OEE - production line status dashboard

21


TrendMiner in practice: Coagulation

22

Problem StatementReactor shuts down once or twice for every CIP (Cleaning In Place) 30 times per year restart

ApproachUse TrendMiner to look for stable and unstable start-ups& Compare these periods



Issue:

Valve opened to

fast

Solution:

changing ramping in

process automation

Searching similar situations and compare

good and bad events.

23



24

Reduction of 30 downtime periods per year.

Business impact


RESULTSCHALLENGE SOLUTION

The technology storm is developing

Avebe developed an operations strategy “Avebe Factory4.0”

Strategic focus on getting value out of data

• Main goal Factory4.0: Transforming Avebe with data

• OSIsoft Enterprise Agreement

• PI System as strategic platform• TrendMiner Corporate Explorer

Program• Reduction of 30 downtimes per

year• Enhanced operational awareness

• More and more technologies coming available on the market

• Additional challenges with an ageing workforce: ~20% will retire within 5 years

Transformation to a data-driven organization

25


Increase asset uptime

Reduce give-away (more water and less protein & starch in product)

Reduce starch, protein & fiber content in waste water

Reduce re-work

Optimize usage of chemicals

Strengthen operational optimization capabilities

Improve data capturing & data visibility across departments

Improve situational awareness regarding energy, CO2 & water consumption across departments

Expand energy mgmt. capabilities

Integrated system for production-, quality- & release-related data

Quality aspects in OEE

In-process quality prediction

Loss Prevention &Asset Health Process Productivity Energy Efficiency &

Water Usage Quality Mgmt.

Opportunities for Avebe

Capability & knowledge sharing

Enable resources by leveraging modern tools appropriately

Talent Acquisition & Retention

26


Laurens Marijns

27

International MES/MOM Coordinator for Actemium

Mobile App powered by NFC and the OSIsoft PI System


• F&B represents a Top 3 industrial segment

• Global company• 21,000 employees• OSIsoft Partner

28

Actemium


Business Challenge

Improve manual data collection

29


Solution

30



Manual CCP’s with NFC

32

Manual Data Collection needed to be improved

Using cell phones, NFC tags, ID Badges, and the PI System Actemium built a solution

Easy to use, integrated app that suits the customers needs

• Modern, available technology• Proven technologies

• Built quickly and efficiently• Insight and tracking into CCP’s• Actionable, real-time information

• Plant Visibility• Compliance• Audit Trail


Isabelle Lacaille

33

Data Infrastructure Engineer with Lonza

PIVOT – Productivity Improvements via Operations Technology


Lonza

34


Red Carpet Incubation Program (RCIP)

Collaboration between OSIsoft and Microsoft• Addresses Industrial IoT Challenges• Jumpstart a data science initiative• Provide better operational insight

35


• Increase in reaction time near the end of 2016

• Root cause: removed trays in distillation column never replaced

• No production disruption, coincided with start-up of second reactor system

Specialty Ingredients | Isabelle Lacaille | 18 September 2019

36

RCIP OutcomesDiscovered optimization potential


Post - RCIP

• Assets, Events, and Data modeled in the PI System• Hired Master’s student for data science• Continued to find opportunities in their plant• Infrastructure Tools: PI Vision, SEEQ, PowerBI, and

Unscrambler

37


Accelerating Process Optimization ProjectsOpportunity #1: Optimize temperature increase during reaction

Data mining revealed golden batches with different temperature profile

High temperature causes evaporation of reactant, leading to slower reaction

Potential capacity increase of 15-18%

TemperatureTemperature Golden BatchHot Oil Flowrate

PressurePressure Golden BatchReactant Flowrate


Accelerating Process Optimization ProjectsOpportunity #2: Optimize timing of reactant dosing

Data mining revealed golden batches with different pressure profile, correlating with reactant

Precise timing of reactant dosage decreases the occurrence of side-reactions

Potential capacity increase of 16-20%

TemperatureTemperature Golden Batch

PressurePressure Golden Batch

Reactant flowrateUnit Operation



Lonza’s PIVOT

40

Lonza wanted to improve its productivity

Leverage people, process, and data collaboratively

Improvements identified with greater operational awareness

• Data contextualization• Reduce data preparation time to a

minimum• Process and data science experts

• Temperature optimization -Capacity increase of 15-18%

• Reactant dosing optimization -Capacity increase of 16-20%

• Identifying bottlenecks

• Plant Visibility• Unknown root causes of batch

variance• Identifying opportunities


Process Productivity Quality Tracking Energy Efficiency Asset Health

Customer Use Cases: Summary


Change overs

Distributed Supply Chains

Batch Management

Operational Agility

Regulatory Compliance

CMA and CPP influence

QMS /Corrective ActionPredicted Quality

Manage environmental impact

Sustainability initiatives

Reduce Utility Consumption

Overall Equipment Effectiveness

CMS Integration with real-time data

Condition based and predictive maintenance

Process Productivity Quality/Safety Energy Efficiency Asset Health

Business Outcomes Enabled by The PI System


Contact information

43

Kevin Geneva• OSIsoft, Philadelphia• [email protected]

The Secret Ingredient in Operational Data and Technology · digital transformation journey? A....

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