Manufacturing - Operational Data Fusion: Adding value with the PI Asset Framework

Transcription

1 Manufacturing - Operational Data Fusion: Adding value with the PI Asset Framework Presented by Dr. Stuart Watson

2 Agenda Quick Intro to Evergreen Business Problem Operational vs. Manufacturing Data Connecting Manufacturing Data to the PI Server Business Solution Conclusion 2

3 Evergreen Packaging Fiber Based Food & Beverage Packaging 2 Mills 13 Converting Facilities (6 US) 2 Filling Machine Manufacturing Plants 3

4 Evergreen Mill Value Chain Image courtesy of nuttakit at FreeDigitalPhotos.net 4

5 Evergreen Converting / Equipment Value Chain Image courtesy of nuttakit at FreeDigitalPhotos.net 5

6 Evergreen and OSIsoft Image Source: SX1857_SY1019_.jpg Image Source: Almost 30 years in the Mills Business Critical 130,000+ PI Tags Hundreds of PI ProcessBooks and PI DataLink Reports 2014 Enterprise Agreement Starting to use Asset Framework Image Source: Image Source: 470x379,0.jpg 6

7 Quick Plug for an Enterprise Agreement Unlimited Technology Online Training Virtual Learning Environment Conferences and Seminars AF Cookbook Solution Recipes Training Credits AF Workshop Evergreen Specific Field Services Managed PI Enterprise Agreement Team Image courtesy of Stuart Miles at FreeDigitalPhotos.net 7

8 Business Problem Quality Investigation Customer Quality Investigations Customer Roll Number Roll: CAW934W181205A 8

9 Business Problem Quality Investigation Quality of Coating Can have Multiple Coatings Spots, Drops, Holes, Streaks, Basis Weight, Caliper, Globs, Strength, Adhesion, Dyne, etc. 9

10 Business Problem Extrusion Quality Investigation Customer Quality Investigations Customer Roll Number to Root Cause Operational Data Machine Specs Running Conditions Manufacturing Data Orders Runs Quality Roll: CAW934W181205A Can take days 10

11 Operational vs. Manufacturing Operational State of the Process Audience Operators / Process Engineers Historian PI Data Archive Manufacturing Results of the Process Audience Product Managers / Book Keepers Manufacturing Execution System OptiVision, Elixir 11

12 Operational vs. Manufacturing cont d Operational Data Timestamp Indexed Quality, Annotations Timeframe - Explicit Seconds / Minutes Manufacturing Data Product Indexed Roll, Reel, Batch, Widget, etc. Timeframe - Implicit Minutes / Hours 12

13 Business Problem Extrusion Quality Investigation Customer Quality Investigations Customer Roll Number to Root Cause Operational Data Machine Specs Running Conditions Manufacturing Data Orders Runs Quality Roll: CAW934W181205A Can take days 13

14 Operational and Manufacturing Data Need to combine different data sets PI System allows aggregation of data Import or connect to external databases Use established toolset 14

15 External Data Connection Options Relational Database Interface SQL pulls data into the PI Data Archive Server PI ODBC Client SQL pushes data into the PI Data Archive Server Foreign Data Sources PI Data Archive Server queries database PI AF Server Tables Imported PI AF Server queries database one time Linked PI AF Server queries database repeatedly 15

16 PI System Explorer Library Tables and Table Connections 16

17 Linked Tables - Connection Create connection to database server Uses standards ODBC OLE DB 17

18 Linked Tables - Table Build Query Parameters allow for greater flexibility 18

19 Business Problem Quality Investigation Customer Quality Investigations Customer Roll Number Reel/Roll ID in PI System Many Control Systems track roll ID Pull/push from MES Roll: CAW934W181205A 19

20 Business Solution Development Reel Data I Query MES data based on Reel ID No timestamp confused clients Not a series no trends 20

21 Business Solution Development Reel Data II Include time data Ensure table time zone set Convert data time to PI Time Timestamp happy clients Not a series no trends 21

22 Business Solution Development Reel Data Problem MES Data has a Reel based Index PI Clients want Timestamp based Index Need to Convert Reel based Index to Timestamp based Index 22

23 Business Solution Development Reel Data Final Realization Each coating machine produces one roll at a time Query based on Machine ID Time series require a time-range Query based on Start and End times No longer based on Reel ID Time-range established in client by filtering on Reel ID 23

24 Business Solution Development Reel Data - Final 24

25 Business Solution Development Reel Data - Final Lookup based on desired time-range Series - Trend 25

26 Business Solution Asset Framework MES data now Timestamp indexed Data treated equally Build Asset Framework Use AF Clients 26

27 Business Solution Extruded Roll Quality Report 27

28 Links to Full Line Overview on PI Coresight 28

29 Business Solution Value Root cause investigation Data gathering gone from days to minutes. Greater Insight All data more accessible 29

30 Lessons Learned Use the 64-bit System Explorer on 64-bit AF servers Timestamp everything you want to trend Watch out for time zones SQL is your friend Take Care with your Queries - impact MES Performance Use parameters in your query Not all AF Attributes are created equal Set a Table Cache Interval 30

31 Next Steps / Wish List More Business Uses Recipe center-lining Use of Event Frames Extract data of interest Investigate Foreign Data Sources Clients see AF Linked Tables and PI Points differently Retrofit PI ProcessBooks Add manufacturing data context 31

32 Conclusion Combining Operational Data with Manufacturing Data Data Observe Actions and Consequences Together Make Data Actionable Add Value 32

33 Manufacturing Operational Data Fusion COMPANY and GOAL Evergreen Packaging deliver the highest standards in quality, on time in full delivery, and customer service CHALLENGE Determining Root Cause on Coat Quality Issues was time consuming SOLUTION Used Linked Tables to Access Manufacturing Data from PI AF structure RESULTS Saves hundreds of skilled hours per year Need Operational Data in Manufacturing context Compilation took several days on several systems Operational and Manufacturing data accessible on an equal footing Frees resources for more involved tasks Report being considered as valueadded customer service 33

34 Contact Information Dr. Stuart Watson Mill Decision Support Systems Architect Evergreen Packaging, Inc. 34

35 Questions Please wait for the microphone before asking your questions Please don t forget to Complete the Survey for this session State your name & company 35

36 Thank You