Empowering Business in Real Time. © Copyright 2009, OSIsoft Inc. All rights Reserved. PI Baking Contest Regional Seminar Series Philadelphia Pete Long PI Administrator Glatfelter, Spring Grove, PA October 13, 2009

2 Empowering Business in Real Time. © Copyright 2009, OSIsoft Inc. All rights Reserved First Paper Machine

3 Empowering Business in Real Time. © Copyright 2009, OSIsoft Inc. All rights Reserved. Todays Paper Machines

4 Empowering Business in Real Time. © Copyright 2009, OSIsoft Inc. All rights Reserved. Spring Grove Architecture… 4 Interface node Analytical tools - Performance Eq. - Control Monitor - Notifications Spring Grove… - ProcessBook - Datalink - Control Monitor Data Source (DCS, PLC, etc) Other systems - ERP - Maintenance - LIMS - CEMS PI Servers …Client stations - ProfileView - SQC - DevNet Utilities Interface node Data Source (DCS, PLC, etc)

5 Empowering Business in Real Time. © Copyright 2009, OSIsoft Inc. All rights Reserved. Glatfelter: Everyone Benefits when everyone is involved. Simply put, the more people that contribute to our PI system, the better the intelligence we get from it. The different perspectives allow us to collectively mine more information from the data. Steve Groetz, Process Automation Manager. Customer Business ChallengeSolutionCustomer Results / Benefits Finite engineering workforce exercising a broad range of disciplines. Limited capitol resources: making do with what we have Wealth of mill wide process data in PI not being effectively interrogated. Create an initiative to generate individual motivation beyond the engineering department to the entire workforce exploiting PI data with goals of improving visibility, reducing time, increasing quality, and reducing costs. ProcessBook & DataLink projects were received from 6sigma black belts, lab techs, and process engineers. Projects were essential to prove a business case, provide real-time process information, and compare current runs to QC standards. On project continues to verify and maintain quarterly savings of over $100k. Pulp and Paper

6 Empowering Business in Real Time. © Copyright 2009, OSIsoft Inc. All rights Reserved. Looking for a Super Hero! 6

7 Empowering Business in Real Time. © Copyright 2009, OSIsoft Inc. All rights Reserved. …easy as PI -or- PI is so easy a… 7

8 Empowering Business in Real Time. © Copyright 2009, OSIsoft Inc. All rights Reserved. OSIsoft Collaboration 8

9 Empowering Business in Real Time. © Copyright 2009, OSIsoft Inc. All rights Reserved. Contest example… Value Now 9 Problem: Inability to trend Control Monitor stats in ProcessBook Solution: Extract data from CM database into Excel and filter, sort, trend and report in Excel Result: Improved visibility of loop performance data

10 Empowering Business in Real Time. © Copyright 2009, OSIsoft Inc. All rights Reserved. Contest example… Value Now 10

11 Empowering Business in Real Time. © Copyright 2009, OSIsoft Inc. All rights Reserved. Contest example… Value Now 11 Real Time PI Data Real Time MES Data Averaged PI Data Problem: QC and Mfg wanted to compare real time scanner data against lab test results as soon as possible Solution: Use ODBC data sets in ProcessBook to access MES system and display lab data and control limits against real time measurements Result: Ability to make control decisions and correct problems in real time. Minimize waste and rework Problem: QC and Mfg wanted to compare real time scanner data against lab test results as soon as possible Solution: Use ODBC data sets in ProcessBook to access MES system and display lab data and control limits against real time measurements Result: Ability to make control decisions and correct problems in real time. Minimize waste and rework

12 Empowering Business in Real Time. © Copyright 2009, OSIsoft Inc. All rights Reserved. Contest example… Value Now 12 Problem: Many grade variations with variable property setpoints hard to document and display Solution: Collect actual properties per run and display so operator can easily compare current to previous runs Result: Visualization of data from prior runs enables operators to quickly and easily see if they are on track for the specific grade and make adjustments in real time.

13 Empowering Business in Real Time. © Copyright 2009, OSIsoft Inc. All rights Reserved. Contest example… Value Now 13

14 Empowering Business in Real Time. © Copyright 2009, OSIsoft Inc. All rights Reserved. Contest example… Value Now 14

15 Empowering Business in Real Time. © Copyright 2009, OSIsoft Inc. All rights Reserved. Contest example… Value Now 15

16 Empowering Business in Real Time. © Copyright 2009, OSIsoft Inc. All rights Reserved. And the Winner is… 16

17 Empowering Business in Real Time. © Copyright 2009, OSIsoft Inc. All rights Reserved. Future Drives… Value over Time 17

18 Empowering Business in Real Time. © Copyright 2009, OSIsoft Inc. All rights Reserved. Future Drives… Value over Time 18

19 Empowering Business in Real Time. © Copyright 2009, OSIsoft Inc. All rights Reserved. Wrap-up… Value Now, Value over Time 19 Project C.M. Trending 3D Profiles Lab Compare Run Properties P.M. Overview Cost vs. Quality Adv. Calc. Tutorial B.R. Efficiency Save Money Save Time Improve Visibility Increase Production Reduce Downtime

20 Empowering Business in Real Time. © Copyright 2009, OSIsoft Inc. All rights Reserved. Glatfelter: Everyone Benefits when everyone is involved. Simply put, the more people that contribute to our PI system, the better the intelligence we get from it. The different perspectives allow us to collectively mine more information from the data. Steve Groetz, Process Automation Manager. Customer Business ChallengeSolutionCustomer Results / Benefits Finite engineering workforce exercising a broad range of disciplines. Limited capitol resources: making do with what we have Wealth of mill wide process data in PI not being effectively interrogated. Create an initiative to generate individual motivation beyond the engineering department to the entire workforce exploiting PI data with goals of improving visibility, reducing time, increasing quality, and reducing costs. ProcessBook & DataLink projects were received from 6sigma black belts, lab techs, and process engineers. Projects were essential to prove a business case, provide real-time process information, and compare current runs to QC standards. On project continues to verify and maintain quarterly savings of over $100k. Pulp and Paper

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