Einsatz und Nutzen von MES in der Prozessindustrie Hisham K. Mubarak

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1 Einsatz und Nutzen von MES in der Prozessindustrie Hisham K. Mubarak 1

2 BASF SE at a glance MES as Key for Operational Excellence Best Practice MES in Process Industry Summary & Outlook 2

3 BASF The Chemical Company Around 400 production sites with around 800 production plants Our chemicals are used in almost all industries We combine economic success, social responsibility and environmental protection Sales 2012: 78,729 million EBIT 2012: 8,976 million Employees (as of December 31, 2012): 113,262 Platzhalter für Bild In 2012, BASF filed for around 1,170 new patents worldwide 6 Verbund sites and around 380 production sites 3

4 BASF worldwide Sites Antwerp Florham Park Ludwigshafen Freeport Geismar Nanjing Hong Kong Kuantan Singapore Regional centers Selected production sites São Paulo Verbund sites Most important research sites 4

5 Verbund site Ludwigshafen The largest integrated chemical complex in the world Headquarter Employees BASF SE 34,769 * Site area 10 km² Sales products about 8.5 million metric tons p.a. Road 106 km Rail 230 km Site traffic 2,100 trucks daily Shipment 100,000 containers p.a. Pipeline system about 2,800 km Production facilities circa 160 production plants 5

6 BASF SE at a glance MES as Key for Operational Excellence Best Practice MES in Process Industry Summary & Outlook 6

7 Achieving Operation Excellence I must improve productivity I must improve quality I need traceability I must minimize downtimes I must reduce costs I need transparency Source: I need to analyze batch performance 7

8 Reality: Complexity is overwhelming process managers Process analysis Analysis of optimization hypothesis require manual data integration from several systems (LIMS, PIMS, DCS alarms, SAP,...) Help!! Digital Tsunami Non-productive tasks reduce time available for process optimization Need for complexity management 8

9 MES Support Management und Optimization of Operational Processes What is MES? Process data analysis Documentation and archieving of production process data Analysis of plant status and operation modes Monitoring of production KPIs Information integration of systems From Data to Information! Manufacturing Execution Systems are tools for automation and support of operational processes in production, quality, logistics and maintenance. MESs manage, monitor and synchronize the execution of real-time, physical processes involved in transforming raw materials into intermediate and/or finished goods. MESs applications provide feedback on process performance, and support component- and material-level traceability, genealogy, and integration with process history. MESs coordinate the execution of work orders with production scheduling and enterprise-level systems. 9

10 Manufacturing Execution Systems are tailored for each plant Production planning Cost Calculation Sales and Delivery Reclamation Management Business focus Operative Condition Produktions- Based und Instandhaltungsplanung Maintenance Production Documentation Bewertung der Prozessund Anlagenperformance Process Data Analysis Batch Monitoring and Analysis Reporting von Verbrauchen, Detailed Scheduling Produktionsmengen und Beständen Information Integration KPI-Monitoring Effizienzsteigerung und Prozessoptimierung... Plant Asset Management Quality Driven Process Control Shift book and report book Operational focus Tank farm control PCS DCS FPLS/ Filling warehouse LIMS Control TCS control TCS Raw material production lab filling Warehouse and delivery 10

11 BASF SE at a glance MES as Key for Operational Excellence Best Practice MES in Process Industry Summary & Outlook 11

12 Plant Information System serve as standard data source for MES applications SAP-Integration Reports Februar Messstelle P_1170.X P_1811.HDAC 06: :48: :20:26 4, AUTOMATIK BAR Druckreglung Druckregelung Wertermittlung Min Max Laufzeit TagesAnfang Mittel Vorgabe 3,8 4,5 AUTOMATIK , , , So 5 24 Mo , , , , Di , , , Mi , , , , Do , , , , Fr , , , , , Sa , , , , So , , , , Mo , , , , Di , , , , Mi , , , , Batch Analysis KPI- Monitoring Process Flow Charts PIMS Trend View (out of the box) Pattern Detection Asset Monitoring 12

13 PIMS Data Analysis Pattern Recognition in PIMS Data Motivation Most data analysis problems require comparison of repeating signal patterns pattern search is done manually Application of specialised tool pattern search in historc PIMS data Features Benefits Support process personnel in analysis of process situations and operation conditions Improve efficiency of root cause analysis for Easy selection of all relevant tags degradation of product quality/ product Easy selection of reference range output Automatic pattern search and result degradation of unit efficiency visualisation Identification of unkown dependencies through Configuration of match tolerance historic data analysis 13

14 BASF BatchExplorer Batch Runtime Monitoring and Analysis Unit Procedure level Operation level Phase level Analyze performance of different units Analyze performance of different operations (of a unit) Analyze performance of different phases (of an operation) 14

15 Manufacturing KPI Monitoring Output?? Cost?? What are the current production cost? How did the new control strategy influence the energy cost? When did I lastly gain a higher output? Output Cost per t of product Monthly report Production amount: 700 t Material cost: 234 /t Energy cost: 67 /t Manufacturing KPI Monitoring 15

16 Overcoming non-standardized data integration Initial situation in 2010 Many non-interconnected automation systems Heterogenous and plant specific integration solutions ( Spaghetti-Integration ) SAP (PP-PI, QM, PM, MM) Asset Monitor Rotating Equipment Asset Monitor Intell. Feldgeräte DCS PIMS Middleware Alarm- Monitor Controller- Monitor LIMS Chromatographie Data System Middleware 0 Warehouse Management Labelling Filling Control Utilities Production Lab Filling Warehouse 16

17 MES Infrastructure Definition and Attributes MES Infrastructure: Defined set of systems, products and technologies that serve the provision of differentiated MES solutions. Main attributes of an infrastructure Openness: Can be used by all user groups in an easy and convenient way Extensibility: Supports flexible integration of new elements to the infrastructure Technology independence: Infrastructure independent of underlying technologies Sustainability: Maintenance and enhancement are efficient and reliable 17

18 User Groups and Roles Production data analysis Production costs Production Manager Centers of Expertise Shift Master Shift report Shift hand-over Plant Manager Asset Manager KPI-Cockpit Performance analysis Process Manager Laboratory KPI Cockpit Asset Effectiveness Batch performacne comparison Input of sample results Root cause analysis Collection of environmental data 18

19 MES-Infrastructure (XHQ) MES Infrastructure Concept Februar Messstelle P_1170.X P_1811.HDAC Tools for Configuration Tools for Visualizat ion and data analysis Standard KPIs Shift Handover report 06: :48: :20:26 4, AUTOMATIK BAR Druckreglung Druckregelung Wertermittlung Min Max Laufzeit TagesAnfang Mittel Vorgabe 3,8 4,5 AUTOMATIK , , , So 5 24 Mo , , , , Di , , , Mi , , , , Do , , , , Fr , , , , , Sa , , , , So , , , , Mo , , , , Di , , , , Mi , , , , Open Interface for external Applications Real Time Data Integration (Access, Context, Calculations, Aggregation, Validation) IP21- Adapter PI- Adapter PHD- Adapter Database Adapter Webservice- Adapter SAP Adapter PIMS IP21 PI PHD PLS PLS LIMS PLS PLS Alarm-DB PLS PLS CPM-DB PLS PLS AMS PLS PLS PLS SAP External Data Sources 19

20 Automatized creation and update of contextual data model Automatic daily synchronization Extract, Transform, Load (ETL) Configurable matching rules Functional location PIMS Tags + MES-I Master Data structure (MDS) 20

21 User configurable interface design Shift Master Plant Engineering 21

22 MES-Applications and Operational Intelligence Full transparency on all data sources Standardized integration of data sources KPI-Cockpit Standard MES Applications SHR Asset Effectiveness Shared information bus with context model (MES-Bus) Tag Explorer Calculations Intranet Standardized MES Applications Trender Visual Tile Composer Intranet Links MES-Infrastructure platform MES-BUS Standard Functionality Visualization Library BDIS Aspen IP.21 / Osisoft PI AE > 160 > 2000 > 150 > 150 > 150 > 150 > 150 PIMS Assets plants plants plants plants plants AM CPM SGU SAP KVP ELP LIMS > 150 plants > 60 LIMS 22

23 Standard Application KPI - Cockpit KPI-Cockpit Functionality KPI - Cockpit Specific raw material consumption Specific energy consumption Alarm Monitoring (AM) User defined plant specific KPIs SHE Safty, Health, Environment Controller Performance Monitoring (CPM) KPI - Cockpit Asset Effectiveness KPIs Qualification KPIs Continuous Improvement KPIs Technical KPIs 23

24 Standard Application Shift Handover Report Shift Handover Report Functionality Maintenance report Shift report book Plant status Tank overview Top 20 Alarms Tank overview Z-circuit status Process deviations Production KPIs Selectivity Maintenance Report Book Plant status Top 20 Alarms Top 20 Control loops 24

25 Simplified Generic MES Landscape per Plant Vertical Integration Solution Manufacturing Operations Management Application Manufacturing Intelligence Solution PIMS Horiz. Integration LIMS 25

26 BASF SE at a glance MES as Key for Operational Excellence Best Practice MES in Process Industry Summary & Outlook 26

27 Summary and Outlook Summary MES Infrastructure is a key driver to harmonize and standardize BASFs MES landscape Major benefit of MES is transparency and automation of process management tasks Ongoing roll-out of XHQ in 3 major European sites Outlook Extension of roll-out scope to other sites as required Implementation of advanced XHQ-based MES applications for batch analysis, production KPI calculation and reporting Extension of current site-oriented structure to multi-site enterprise MES-Infrastructure From Data to Information! 27

28 28

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