jason laberge honeywell asm® consortium outreach seminar june 13th, 2008 kuala lumpur, malaysia...

Jason LabergeJason LabergeHoneywell

ASM® Consortium Outreach Seminar

June 13th, 2008

Kuala Lumpur, Malaysia

Introduction to ASMIntroduction to ASM Introduction to ASMIntroduction to ASM

OperatioOperations ns OutreacOutreach h SeminarSeminarThis document and the information contained herein are confidential to the ASM Consortium and the property of Honeywell International, and are

made available only to ASM Consortium member company employees. This document, and any copy thereof, and the information contained herein shall be maintained in strictest confidence; shall not be disclosed or distributed (a) to persons who are not ASM Consortium employees, or (b) to ASM Consortium employees for whom such information is not necessary in connection with their assigned responsibilities. When the employee in possession of this document terminates employment with the ASM member company, this document and any copies thereof shall be returned to the employee’s manager. There shall be no exceptions to the terms and conditions set forth herein except as authorized in writing by the responsible ASM Program Manager in accordance with the provisions of the ASM Consortium Agreement.

ASM® and Abnormal Situation Management® are registered trademarks of Honeywell International

Contains ASM Consortium Proprietary Information

ASM Consortium Proprietary

ASM

Presentation OverviewPresentation Overview

• What is the ASM Consortium

• The ASM Problem

• ASM History and Program Periods

• Organizational Structure

• ASM Website

• Discussion/Questions


ASM

Abnormal Situation Management® A Joint Research and Development

Consortium

Abnormal Situation Management® A Joint Research and Development

Consortium

Human Centered SolutionsHuman Centered SolutionsHelping People PerformHelping People Perform

Founded in 1994

Creating a new paradigm for the operation of complex industrial plants, with solution concepts that improve Operations’ ability to prevent and respond to abnormal situations.

www.asmconsortium.org


ASM• An industrial process is being disturbed and

the automated control system can not cope...

• Consequently, the operations team must intervene to supplement the control system.

• Impacts profitability in multiple ways:

What is an Abnormal Situation?What is an Abnormal Situation?

Product Quality

Product ThruputPersonal Injury

Loss of Life

Equipment Damage

Job Satisfaction


ASMASM

Operating Target

Lost Profit

(Lost Capital)

(Lost Revenue)

Loss

Profit

Shutdown

Incident

Normal

Break-even

Pla

nt P

rodu

ctio

n Le

vel

Time

Accidents, while rare, add Costs$10B annually in US alone

Accidents, while rare, add Costs$10B annually in US alone


ASM

Fundamental ASM ProblemFundamental ASM Problem

The Paradox of Automation…

• Better automation leads to more sophisticated processes

• More sophisticated processes leads to more opportunities for error

• We “fix” the increasing errors with still more automation

When things go wrong, people have difficulty

intervening to correct the problem!

Poor User Centered Automation


ASM

Unexpected Events Cost 3-8% Capacity

> $10B annually in Lost Production

Unexpected Events Cost 3-8% Capacity

> $10B annually in Lost Production

Plant Operating Target

Plant Capacity Limit

Daily Production LevelDaily Production Level

Day

s p

er Y

ear

Optimization efforts

Operational Constraints

95% 100%< 60%

Total Feed

0

5

10

15

20

280

290

300

310

320

330

340

350

360

370

380

390

400

410

420

430

440

450

460

470

480

490

500

510

520

530

540

550

560

570

580

590

600

610

620

Rate

# D

ays

$33.5 M

Total Feed

02

46

810

1214

1618

280

290

300

310

320

330

340

350

360

370

380

390

400

410

420

430

440

450

460

470

480

490

500

510

520

530

540

550

560

570

580

590

600

610

620

Rate

# D

ays $38.5 M

0

50

100

150

200

250

300

112

115

118

121

124

127

130

133

136

139

142

145

148

151

154

157

160

163

166

169

172

174

177

180

183

Production rate

Freq

uen

cy

3.2%5.8%

0

50

100

150

200

250

300

457

463

468

474

480

486

492

497

503

509

515

520

526

532

538

543

549

555

561

567

572

578

584

590

595

Feed Rate

Freq

uen

cy

1503

$24.2M

Summarized Production Data

Plant Incidents

33.5M

38.5M

24.2M

5.8% Source: ASM Consortium Research


ASM

ASM Solutions Minimize Impacts$MM Added to the Bottom Line

ASM Solutions Minimize Impacts$MM Added to the Bottom Line

(Higher) Plant Operating Target

Recovery of 3-8% of Capacity

ASM EffortsASM Efforts

Daily Production LevelDaily Production Level

Day

s p

er Y

ear

95% 100%< 60%

Plant Capacity Limit

Operational Constraints


ASM

ASM Consortium HistoryASM Consortium History

• 1990 - Formed an Alarm Management Task Force• 1992 - Asserted need to go beyond alarm management• 1993 - Project to understand abnormal situation management

with 4 of Honeywell customers• 1994 - Generated ASM problem statement and solution

requirements document• 1994 - Founded the ASM Joint R&D Consortium - 10 companies• 1995 - Started NIST ASM Collaborative Decision Support

Program• 1998 - Established ‘Designed for ASM’ products/services • 1999 - Decided on 3-year short-term research to field concepts• 2002, 2005 - 3-year programs with emphasis on closing gaps on

effective operations, development, and deployment• 2008 – New 3-year program with focus on metrics and

communications to increase the Consortium role in industry


ASM

ASM Organizational StructureASM Organizational Structure

ASM DirectorPeggy Hewitt (HON)

DevelopmentDoug Metzger (HON)

ResearchJason Laberge (HON)

CommunicationsPeggy Hewitt (HON)

Prog. MngmtLiana Kiff (HON)

User MemberReps

AssociateMember Reps

UniversityMember Reps

DevelopmentSubcommittee

Incorporating ASM into Products,

Services

ResearchSubcommittee

Understanding ASM, Solution

Concepts

CommunicationsSubcommittee

Dissemination of ASM Knowledge

ASMFunding

MemberDues

Leadership Team

HoneywellFunds


ASM

ASM Website (External)www.asmconsortium.orgASM Website (External)www.asmconsortium.org


ASM

ASM Website (External) www.asmconsortium.orgASM Website (External) www.asmconsortium.org


ASM

ASM Website (Internal) www.asmconsortium.orgASM Website (Internal) www.asmconsortium.org


ASM

Discussion/QuestionsDiscussion/Questions

• Thank You!

• Questions and/or Comments– How does ASM related to existing improvement

programs like OPI?

jason laberge honeywell asm® consortium outreach seminar june 13th, 2008 kuala lumpur, malaysia...

Documents

asm consortium employees

asm problem asm history

asm consortium agreement

asm consortium research

asm member company

employees manager

abnormal situations

sophisticated processes