SF 02 07B Richardson Irving

Leveraging PI to Deliver Standardized Downtime Reports: 

Leveraging PI to Deliver Standardized Downtime Reports A Solution for Corporate Downtime Reporting

Agenda: 

Agenda Introductions Business Challenge Solution Description Resulting Benefits Future Plans

Introductions: 

Introductions Jordan Richardson, Irving Group Moncton Project Engineer, Electrical Implemented the Downtime System at Irving Personal Care Will over see the corporate roll-out for downtime and related KPI reporting

Slide4: 

Introductions

Slide5: 

Introductions Forest Products Consumer Products Petroleum Products Irving Oil Largest and most environmentally advanced refinery in Canada – Capacity of 250,000 barrels per day. Irving Lubricants Blender and packager of premium petroleum products. J. D. Irving, Limited Largest private reforestation program in Canada. A full range of forest products: Lumber Pulp Paper Corrugated Medium Irving Tissue Leading manufacturer of premium quality tissue products – branded and private label. Irving Personal Care New company – Private label diapers and training pants for North American retailers.

Slide6: 

Introductions Industrial Manufacturing Shipbuilding Kent Homes Modular buildings – commercial & residential. Strescon Pre-cast, pre-stressed concrete products. Ocean Steel Fabricated steel structures. Food Processing Cavendish Farms 4th largest processor of frozen potato products in North America. Serving retail, food service and quick service restaurants. Transportation Services Midland Transport Sunbury Transport Kent Lines Atlantic Towing RST Industries NB Southern Railway Other Businesses Home improvement stores Construction and engineering services Truck parts & service Media Fertilizers & agricultural services

Introductions: 

Introductions Moncton Group

Introductions: 

Introductions Irving Personal Care 150,000 sqft State of the art facility 750 diapers per minute 3.5 million cases

Business Challenge: 

Business Challenge Diverse business units, interests vary but units have common goals Continuous improvement required a solution for corporate downtime reporting Critical to improving plant efficiency Corporate meant a common approach to both collecting data and calculating numbers, critical to buy-in on the plant floor

Business Challenge: 

Business Challenge Create a downtime system to be accepted across the organization. To be: Simple, easy to use and understood integrated with plant controls in real time functionally transparent in plants with no control integrated with corporate MSSQL databases for business applications and WEB based reporting

Solution Description: 

Solution Description ADM was awarded a contract to implement a downtime system at the IPC plant. Based on PI and Duet™ technology. Unique to corporation and generic for business units, regardless of automation infrastructure

Introductions: 

Introductions Keith Flynn, P.Eng. VP, Data Management, ADM Systems Engineering Electrical & Computer Science background Automation, process control & data Led five projects for automatic delivery of real time OEE, downtime and related KPI reports

Introductions: 

Introductions ADM Systems Engineering Ltd. Engineering and software development OSIsoft Silver Partner Developer of Duet™ Successfully completed downtime, uptime and event reporting projects

Solution Description: 

Solution Description Functional Requirements Automated, real-time downtime event tracking Events accessible for operators to view & modify Reporting Security Configuration toolset Data transfer to external database

Solution Description: 

Solution Description Duet Technology 4th Generation A suite of software working in concert with PI to deliver event based Key Performance Indicators (KPI’s) and root cause. A flexible system utilizing Microsoft technology Leverages the power of PI RtAnalytics (PI, PI MDB, Event Framework and PI-ACE) to automatically deliver real time, client defined downtime or industry standard OEE reports

Solution Description: 

Solution Description Duet Technology Features Configuration wizards Integrated with PI Batch, BatchView Reporting that supports Time weighted results, proportional to actual loss, accurate to your tag scan rate. Relative time stamps for real time monitoring Recalculation based on updated data Results retroactive to the creation of your PI tags Dynamic reporting intervals for hour, shift, week or month.

Solution Description: 

Solution Description Prerequisite software PI Enterprise Server PI Batch PI ACE PI SDK .Net ASP Server with IIS 5.0 or better

Solution Description: 

Solution Description Core Module Creates record Bases on I/O in PI MBD Calculates KPI’s OEE Downtime Speed & Quality Loss

Solution Description: 

Solution Description

Solution Description: 

Solution Description Configuration Toolset GUI Add or delete Divisions Plants Production lines Machine centers Root causes Security levels

Solution Description: 

Solution Description Configuration Toolset

Solution Description: 

Solution Description Data Transfer Module Moves Data From PI Batch Subsystem to MS SQL

Solution Description: 

Solution Description Data Transfer Module

Solution Description: 

Solution Description Application Reporting Interface Active X Presents Data Allows Manual Entry & Validation Packages information for easy integration with visual and reporting envoirnoments ASP Crystal MS Excel

Solution Description: 

Solution Description Main Screen Provides Navigation ASP.NET Links: Operator, Manual Entry Validation Reports

Solution Description: 

Solution Description Operator Screen View event ASP.NET

Solution Description: 

Solution Description Event Screen Edit event

Solution Description: 

Solution Description Event Screen Split events

Solution Description: 

Solution Description Event Screen Select multiple events

Solution Description: 

Solution Description Validation Report

Solution Description: 

Solution Description Validation Screen Trends Tabulates

Solution Description: 

Solution Description Event Screen Manual entry

Solution Description: 

Solution Description Reports Summary WEB or PDF

Solution Description: 

Solution Description Reports Root Cause WEB or PDF

Solution Description: 

Solution Description Reports Location WEB or PDF

Solution Description: 

Solution Description Reports Problem WEB or PDF

Solution Description: 

Solution Description Reports Cause WEB or PDF

Solution Description: 

Solution Description Analysis and Trouble Shooting

Benefits: 

Benefits Increased profits from focused plant production improvements. Standardized and automated delivery of real time plant equipment KPI’s and related information, across your organization. Improved Root Cause data for in-depth analysis.

Benefits: 

Benefits Centralized data Scalable to roll out across plants Built on Standard Tools (Microsoft and OSIsoft) Web Based True tracking of Unplanned Downtime duration Highlights Bottlenecks and Problems

Future Plans: 

Future Plans Irving Group Roll out the downtime system to plants across the organization Use the data to focus on areas requiring improvement

Future Plans: 

Future Plans ADM Systems Engineering Foundation .Net 2.0 MS Studio 2005

Summary: 

Summary The project delivered a corporate downtime system that is Simple, easy to use and understood integrated with plant controls in real time functionally transparent in plants with no control integrated with corporate MSSQL databases for business applications and WEB based reporting

Summary: 

Summary The project delivered a corporate downtime system that is Being accepted in other plants Providing a tool to focus efforts to improve efficiency and increase profits

Slide45: 

Thank you Questions?

Contact Information: 

Contact Information Irving Group Jordan Richardson richardson.jordan@jdirving.com ADM Systems Engineering Ltd. Keith Flynn keith@admse.com www.admse.com www.duetsuite.com