kpi/metrics for the process industry - automation · pdf filekpi/metrics for the process...

KPI/Metrics for the process industry

Charlotta Johnsson

A company is considered a Business Mover

if it has improved:

a) More than 10% on one or many of the financial metrics

b) More than 1% on over half of the financialmetrics

From: MESA survey ”Metrics that Matter”, Oct 2006.

Typical for Business Movers is that they:

1) Have well defined KPIs

2) Have informed employees

3) use IT systems to get measurements, calculate Key Performance Indicators (KPIs,

Metrics) and display the results.

From: MESA survey ”Metrics that Matter”, Oct 2006


Charlotta Johnsson

CHALLENGES:1) What key performance indicators are used in process industry today?2) Do the key performance indicators differ depending on company characteristics?3) How can key performance indicators be exchanged between differentsoftware-applications?

PROJECT:• PiiA financed project (jan2015-dec2016) called “PiiA-Metrics”

Inte

gratedin

form

ation

han

dlim

g

ManufacturingOperations Management

Control System

Business System

Key performance indicators (KPIs) are metrics designedto visualize, assess, and manage the performance ofspecific operations within enterprises.

What is a KPI?

Performance Management:

1. Awareness of current situation

2. Clear view of the desired situation

3. Improvement potentials

4. Improvement

Functional Model of an Enterprise (ISA95)

6

Level 4

Level 1

Level 2

Level 3

Business Planning & LogisticsPlant Production Scheduling,Operational Management, etc

Manufacturing Operations ManagementDispatching Production, Detailed ProductionScheduling, Reliability Assurance, ...

DiscreteControl

1 - Sensing the production process, manipulating the production process

2 - Monitoring, supervisory control and automated control of the production process

3 - Work flow / recipe control to produce the desired end products. Maintaining records and optimizing the production process.

Time FrameShifts, hours, minutes, seconds

4 - Establishing the basic plant schedule - production, material use, delivery, and shipping. Determining inventory levels.

Time FrameMonths, weeks, days, shifts

Level 0 0 - The physical production process

ContinuousControl

BatchControl

Level 5Company Management

5 - Receive sales orders, assure shipping and customer relations.

Time FrameYears, Months

9/16/2015

ISA 95 – Activity Model for Production Operations

Productiondatacollection

Productionexecutionmanagement

Productionresourcemanagement

Productiondispatching

Productiontracking

Detailedproductionscheduling

Productdefinitionmanagement

Level 1-2 Process Control

Productionperformanceanalysis

Equipment and processspecific production rules

Operationalcommands

Operationalresponses

Equipment and processspecific data

Level 3

Level 4 Business Planning & Logistics

Product Definition

Production Capability

Production Schedule

Production Performance

Level 4

Level 1-2

Earlier work

ISO 22400 is an international standard• Lists 34 commonly used KPIs• Standard released in 2014• Used today in e.g. MES-

product development

Source: ISO 22400 – Part1 (2014)

KPI definition

Content:

Name

ID

Description

Scope

Formula

Unit of measure

Range

Trend

Context:

Timing

Audience

Productionmethodology

Effect modeldiagram

Notes

1: What KPIs are used today?

1: What KPIs are used today?

Include KPIs used in Process Industry

• Find commonly used KPIs in PI• Interviews with companies (5 signed up)• Describe KPIs according to table-structure• Other findings

2: Do the KPIs differ depending on company characteristics

Company characteristics:• Continuous (CO) vs Discrete Object (DO)• Speculation (SD), Hybrid (HD) or Customer-order Driven (CD)• Continuous (CM), Intermitent (IM) or One-time Mode (OM)

3: How can KPIs be exchanged?

KPI definition

KPI definition property

KPI instance

KPI instanceproperty

KPI value

KPI rangeKPI resource

reference

0…N 0…N

0…N1 1 0…N

0…N 0…N

UML models are used to define the structure of a KPI

UML is an implementation independent specification format.

3: How can KPIs be exchanged?UML models are used to define the structure of a KPI

class KPI Object Model

KPI Definition

+ ID

+ Name [0..1]

+ Description [0..*]

+ Scope [0..*]

+ Formula [0..1]

+ UnitOfMeasure [0..1]

+ Trend [0..1]

+ Timimg [0..1]

+ Audience [0..*]

+ ProductionMethodology [0..*]

+ EffectModel [0..*]

+ Notes [0..*]

KPI Value

+ ID


+ Name [0..1]

+ Value [0..1]


KPI Definition

Property

+ ID


+ Value

KPI Instance Property

+ ID


+ Value

KPI Value Property

+ ID


+ Value

Resource Reference

+ ID


+ ResourceType

+ ResourceID

KPI Range

+ ID


+ LowerLimit

+ UpperLimit

KPI Instance

+ ID


+ Name [0..1]

+ Scope [0..*]

+ Formula [0..1]


+ Trend [0..1]

+ Timimg [0..*]

+ Audience [0..*]

+ ProductionMethodology [0..*]

+ EffectModel [0..*]

+ Notes [0..*]

KPI Definition Time

Range

+ StartTime [0..1]

+ EndTime [0..1]

+ Recurrence [0..1]

+ Duration [0..1]

KPI Instance Time

Range

+ StartTime [0..1]

+ EndTime [0..1]

+ Recurrence [0..1]

+ Duration [0..1]

KPI Value Time Range

+ StartTime [0..1]

+ EndTime

+ Recurrence [0..1]

+ Duration [0..1]

0..* 0..10..* 0..*0..* 0..*

1

+is defined in

0..*1

+is defined by

0..*

0..*

0..*

0..*

0..*0..*

0..*0..*

+may be used in

calculation of 0..*

0..*

+may be used in

calculation of 0..*

0..*


KPI definition

KPI definition property

KPI instance

KPI instanceproperty

KPI value

KPI rangeKPI

resourcereference

0…N 0…N

0…N1 1 0…N

0…N 0…N

UML models define the KPI structure

Information

Provider

Information

Requestor GetKPIDefinition

ShowKPIDefinition

UML models are translated to XML schemasXML schemas can be exchanged between various systems

UML model: a software independent representation of the information to be exchanged


Exchanging KPIs

XML schemas for KPIs, an implementation proposal for the information to be exchanged

<KPIDefinition><ID> </ID><Description> </Description><Name> </Name><Scope> </Scope><Formula> </Formula><UnitOfMeasure> </UnitOfMeasure><Range>

<ID> </ID><Description> </Description><LowerLimit> </LowerLimit><UpperLimit> </UpperLimit>

</Range><Trend> </Trend><Timing> </Timing><Audience> </Audience><ProductionMeth.> </ProductionMeth.><Notes> </Notes>”

</KPIDefinition>


XML schemas are refered to as KPI-ML

KPI-ML was released by MESA, May 2015

Available at MESAs homepage www.mesa.org


Charlotta Johnsson

CHALLENGES:1) What KPIs are used in process industry today?2) Do the KPIs differ depending on company characteristics?3) How can KPIs be exchanged between different software-applications?

OTHER topics: navigation among KPIs, finding target-values to the KPIs, KPI lifecycle management.RELATED TO: active participation in ISO22400 and MESA



Charlotta Johnsson

CHALLENGES:1) What KPIs are used in process industry today?2) Do the KPIs differ depending on company characteristics?3) How can KPIs be exchanged between different software-applications?

OTHER topics: navigation among KPIs, visualization, finding target-values to the KPIs, KPI lifecycle management.RELATED TO: active participation in ISO22400 and MESA


23

The following 34 KPIs are defined in ISO 22400 – Part 2

KPIs defined

6.1 Worker Efficiency6.2. Allocation Ratio6.3. Throughput rate6.4. Allocation efficiency6.5 Utilization efficiency6.6. Overall equipment effectiveness index6.7 Net equipment effectiveness index6.8 Availability6.9 Effectiveness6.10 Quality Ratio6.11 Setup Rate6.12 Technical efficiency6.13 Production process ratio6.14 Actual to planned scrap ratio6.15 First pass yield6.16 Scrap ratio6.17 Rework ratio

24

The following 34 KPIs are defined in ISO 22400 – Part 2

KPIs defined

6.18 Fall off ratio6.19. Machine capability index6.20 Critical machine capability index6.21 Process capability index6.22 Critical process capability index6.23 Comprehensive energy consumption6.24 Inventory turns6.25 Finished goods ratio6.26 Integrated goods ratio6.27 Production loss ratio6.28 Storage and transportation loss ratio6.29 Other loss ratio6.30 Equipment load ratio6.31 Mean operating time between failures6.32 Mean time to failure6.33 Mean time to restoration6.34 Corrective maintenance ratio

Functional Model – NNE Example

HistorianSystem

Finance Management

Production Management

Maintenance Management

Learning & Training

Quality Management

Electronic Document

Management

LaboratoryManagement

MESSpec

Management

MESResource

Management

MESPlanning & Scheduling

MESExecution

MESData

Collection

MESAnalysis

MESTracking

BMS System PEMS System DCS System SCADA System

PLCSystem

PATSystem

Q

PRISM

S9

5 L

evel

2S

95

Level

3S

95

Level

4

Process Industry

• Pulp & paper

• Chemicals and plastics

• Petroleum

• Pharmaceutical

• Mining

• Iron and Steel

• Food

Source: IVA 2006

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