click to edit master title style empowering business in real time. © copyright 2010, osisoft llc...

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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


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



• 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


© Copyright 2010, OSIsoft LLC All rights Reserved. 4 Empowering Business in Real Time.

Enabling Awareness The Value of Real-Time



Assessment of Condition

Electrocardiogram

• Statement of “goodness”• Actionable• Critical

The Value of Real Time

Forecast



Creation of OpportunityOnline Financial Market Price Quotations

• Accessible• Responsive• Tactical





Evidence of ChangeClimate Change Data

• Convincing• Intuitive• Impactful



Fuel flow spikes discovered costing $93,000 / year.

Wasted Fuel Gas


Fundamental Principle



TARGET FUEL FLOW

Another Opportunity – Continuous Improvement




Capturing opportunities requires the right people.

The Challenge of Real Time



Delivering Opportunity The Need for Infrastructure



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



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.



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



Process ContextGraphics

Analytical ContextSpreadsheets and Reports

Performance ContextProcess Calculations

Accessible by Users



Contextual by Asset for Efficient Extension



Asset Context

Relational DataReal Time Data

Formulas User Defined

Asset elements derived from a common template for each

equipment type

Contextual for Information Integration



Contextual for Users and Applications



Overcoming the Challenge Performance Intelligence



Benchmarking Performance Against Objectives

Articulation of Performance Rules

Accountability of Manufacturing Objectives

Collaboration Driven by Transparent Accountability



Organizational Presentation of Real-time Opportunities

PI WebParts 2010 for Microsoft SharePoint 2007 or SAP Enterprise Portal



Email with links relevantinformation

Integration with Virtual Prescience Technology

Event-based Notification of Real-time Opportunities

PI Notifications (PI System 2010)



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



• 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



New Performance Intelligence Tools

Microsoft Excel 2010 with PowerPivot for Data Cube Analysis



• 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



Collaborating to Improve The Real-Time Infrastructure in Action



Enterprise Integration of Operational Data from

Wind Farms

John Mostek, O&M EngineerJohn Deere Renewables

OSIsoft 2010 User’s Conference


29 Value now. Value over time. © Copyright 2010, OSIsoft LLC All rights Reserved.

Operating Commissioning Construction Operations Center

Project Locations



Enterprise Management System

PI is the foundation on which our EMS is built, and is the basis for dashboards monitored in our Operations Center



Aggregation controls(AF / MDB hierarchy)

Time controls

Dashboards

SharePoint portal environment on intranet, using PI WebParts



Real-time Status Displays

PI ProcessBook rich client application



Geospatial Context

Customized code to overlay real-time PI data in the Google Earth environment



Production Forecasting

Web services with PI data queries, served up in Business Objects using Flash



Alarms and Notifications



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



Information Driven Collaboration

Kodak

“Energy ManagementThe Infrastructure Approach”

Dr. J. Patrick Kennedy,

CEO and President, OSIsoft



Information Driven CollaborationKodak Park



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



Employee Portal



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



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



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



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.



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



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



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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