deployment of the pdh infrastructure at verallia

Presented by

© Copyr i gh t 2013 OSIso f t , LLC.

Deployment of

the PDH

Infrastructure at

Verallia

Pedro Baptista, Project Manager

Vincent Turck, Industrial IT Director


2nd leading international glass manufacturer in 2012

– 3.8 billion in sales

– Approximately 25 billion bottles and jars produced in 2012

– Industrial presence in 14 countries, with 58 sites (46 glassmaking production sites), 10 technical centers and 94 furnaces

– More than 14,000 employees around the world

– Commercial presence in 46 countries with over 10,000 customers

– 13 innovation awards in 2012

A worldwide leader attentive to its

customers

2


2012 Sales:

3.8 billion Euros

3

In millions € 2012 2011

Sales (*) 3,792 3,628

Operating Income (*) 414 448

EBITDA (*) 656 685

Capital Expenditure (*) 285 272

Still wines

29%

Sparkling wines

9% Spirits

10%

Food

18%

Other bottles

9%

Other (including

tableware and decoration)

4%

Beer

21%

By End Market

Western Europe

56% Eastern Europe

3%

South America

8%

United States

33%

By Geographical Area

© Copyr i gh t 2013 OSIso f t , LLC. 4

A worldwide industrial and commercial presence, aligned

with the markets (*)

4

Industrial presence in 13 countries Commercial presence in 45 countries 44 industrial sites

(*) excluding Verallia North America


PDH Project : Process Data Historian

PDH is an Infrastructure to collect, store and publish raw data directly from the field. PDH uses the PI System from OSIsoft.

PDH is a global system and PI Server & PI AF Server are installed in a central Datacenter.

Business Applications will be developed on top of this PDH Infrastructure.

5 5


PDH : Data Flow

6


PDH : Central Architecture

7


PDH Pilot : Compressor & IS Air Application • Objectives

– Control the Compressed Air production and consumption.

– Analyze data to find the optimize process.

• Benefits Reduce Cost

8


– 39 Sensors to measure flow, pressure, temperature

• All compressors

• Furnace

• Cold End

• 2 Machines (2x Tandem)

– Every half machine equipped separately

– Measurement devices for Power.

– Measurement devices for Hydrometric point

9

PDH Pilot : Compressor & IS Air Application Scope


Architecture of PDH compressed air solution

10


Compressed Air deployment : Feedbacks

11

Some IS machines consume three times more air than others.

Some systems consume more air than theorical model.

Compressor Control Command was setup with wrong parameters.

Operators were not following industrial rules and were wasting air during job changes.


PDH : choosing our optimal clients tools V1 Data are accessible via PI AF only in order to use “Element Relative Display”

One Single PI ProcessBook for Operators.

Heavy VB development in PI ProcessBook (mainly to switch from one plant to another) : Slow response time.

One Single PI ProcessBook not relevant for our central architecture.

One Excel PI DataLink file for client reporting

Excel is slow mainly due to PI AF browsing.

12


Common element

structure for all

countries & plants.

Standard Attributes

Naming

Last Level is

specific to each

plant

PDH : choosing our optimal clients tools V1


Data are accessible via PI AF only in order to use “element relative display”

One PI ProcessBook per Plant for Client Operators

PI ProcessBook is much faster. Easy to develop.

Multiple PI ProcessBook files to manage and update.

SAP BusinessObjects with PI OLEDB for reporting

PI OLEDB difficult to implement. TechSupport was involved to help.

One common and global reporting tool.

Merging SAP Data is also possible.


16


Data are accessible via PI AF only in order to use “element relative display”

One home made web application based on PI AF SDK for all operators.

Web Based Application

Fast access to different plant organization

Automatic screen setup mapped on PI AF model structure.

Very Easy to update.

Home made application more difficult to maintain.

SAP BusinessObjects with PI OLEDB for reporting

PI OLEDB difficult to implement.

One common and global reporting tool.

Merging SAP Data is also possible.

PDH : choosing our optimal clients tools NEXT

19


PDH : choosing our optimal clients tools NEXT


PI

& A

F

Se

rve

r

PI

Inte

rfac

e

Se

rve

r Verallia

Industrial IT

Local

Industrial IT

Local

Project Manager

Shop floor

operator

Administration

Configuration

Standardization

TAG & Structure

Creation

TAG Definition

Nothing

Standardization

Support Nothing

Administration

Configuration

Se

cto

r

Ap

plic

ati

on

s

Support

Creation

Deploy

Manage

Lo

ca

l

Ap

pli

ca

tio

ns

Nothing

Nothing

Specifications

Testing

Training

Use

Use

Creation

Deploy

Manage

Support

Specifications

Testing

Training

PDH : Team Roles

21


PDH : Summary, our Client Strategy for now

Local Applications : PI ProcessBook

Specific Reports : PI DataLink

Global Applications : Web Application (home made)

Global Reports : SAP BO

22


Contacts

Pedro Baptista

[email protected]

Project Manager

Verallia

Vincent Turck

[email protected]

Industrial IT Director

Verallia

23

mailto:[email protected]








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