1. Production visibility: KPI’s in Real-time BASF – The Chemical Company
Thank you for joining me today.
I am Sharon Brown from Wonderware and am presenting a client in the Eastern Cape that was unfortunately called away to important meetings and could not join us.
The study is about PROODUCTION VISIBILITY BY PROVIDING Real-time Key Performance Indicators to the users.
Sharon Brown
Wonderware S.A.

2. Introduction
BASF - The Chemical Company
“We were able to reduce scrap, downtime and smoothed change-overs by the increase in total visibility of our production process”
Quote
“We were able to reduce scrap, downtime and smoothed change-overs by the increase in total visibility of our production process” from BASF:

3. Introduction Agenda Project Solution Benefits Considerations Summary
Agenda - Introduction

4. BASF – Chemical Company
International Company
Diversified foot print around the world
Chemicals are it main business
In South Africa, it includes plastics, polyurethanes, agricultural, leather, chemical and automotive sectors.
BASF Port Elizabeth
Catalytic converter industry
One of the highest users of precious metals for the automotive sector
Roughly 39% market share, which represents roughly 5.5 million parts in 2008.
Foot print
Chemicals are it main business
BASF Port Elizabeth
Catalytic converter industry
A petrol converter consistent of a single converter, as the main aim is to “catch” the carbon emissions. A diesel converter
Mixing slurry and coating process
Process involved is a top down process, beginning with slurry manufacturing on-site.
Involves mixing various acids, precious metals, di waters and various stabilisers, in order to make the mix required by each customer.
Each customer has different specifications for their parts. Roughly 300 slurry types.
Mixing of slurry and subsequent QC and QA testing and approval occurs before production coating can commence.
Reason is primarily weighted in the favour of managing waste, and ensuring the slurries are correctly made, as waste of precious metal is expensive!
Production is done on the bottom level, where various types of machines are used depending on the technology which is being coated.
BASF is one of the highest users of precious metals for the automotive sector
BASF has roughly 39% amount of market share, which represents roughly 5.5 million parts in 2008
4. roughly 39% amount of market

5. Process Background Slurry Manufacturing Q/A Production Mixing
Customer / Part Specific
Slurry are mixed
Q/A
Quality checks
Manage waste
Production
Coating lines
Various machines – client chosen technology
SLURRY AREA
MIXING AREA
LABORATORY / QA
Slurry manufacturing on-site.
This involves mixing various acids, precious metals, di waters and various stabilisers, in order to make the mix required by each customer. Each customer has different specifications for their parts, and varies in pm content, volume etc. Roughly 300 slurry types exist.
Mixing of slurry and subsequent QC and QA testing and approval occurs before production coating can commence. Reason is primarily weighted in the favour of managing waste, and ensuring the slurries are correctly made, as waste of precious metal is expensive!
Production is done on the bottom level, where various types of machines are used depending on the technology which is being coated. For instance, the catalyst for a Renault, compared to diesel 4x4 varies in both coating technique, to physical size, and emission type, and thus the type of machine used can be very different. A petrol converter consistent of a single converter, as the main aim is to “catch” the carbon emissions. A diesel converter has two components, the first being similar to a petrol catalyst, to catch the emissions, the second converter being much larger, to catch the soot emissions. The soot converter flushes itself with the back burn process.
COATING LINES
PRODUCTION AREA

6. Introduction Agenda Project Solution Benefits Considerations Summary

7. Topology - Before new installation
Network TCP/IP (LAN)
MIXING AREA
PRODUCTION AREA
SLURRY AREA
LAB / QA
InTouch SCADA
LIMS – ORACLE DB
MS SQL Server
InTouch
22 Stations
Appr I/O
25 K Historian
10 A/F Clients
Siemens (S7) on
Ethernet
Topology

8. No real-time visibility of the process.
Key Requirements
No real-time visibility of the process.
Equipment Status
Process Status
Maintenance Status
Lack of communication between production and maintenance staff due to lack of information.
No access to key performance indicators
Production variables
Production Rate / Figures
key requirements
No real-time visibility of the process.
Equipment Status – Downtime of equipment
Process Status – where are they in the production process
Maintenance Status
Lack of communication between production and maintenance staff due to lack of information.
No access to key performance indicators
Production variables
Production Rate / Figures

9. Key Requirements More central monitoring of production flow
The information was only available at SCADA level at the machine
Required access to production reports by management
More central monitoring of production flow
The information was only available at SCADA level at the machine
It was only the operator that had access to production and machine statusses, alarms etc.
Data availability to both maintenance and production
Any problems occurring on the lines, had to be carried over by the operators on the line
Always after-the-fact and unclear who’s responsibility it is.
Required access to production reports by management
There were no reporting automatic reporting structure in place.
No summarized data on a production run that included both production, Q&A and maintenance related figures.

10. Project Goals - Technical
Install a central repository of real-time data that links the current SCADA’s, production databases and LIMS data.
Capitalize on already available infrastructure of Wonderware SCADA and Historian
Make the operation more visually representative to all involved using a Web interface
Install a central repository of real-time data that links the current SCADA’s, production databases and LIMS data.
Capitalize on already available infrastructure of Wonderware SCADA and Historian
Make the operation more visually representative to all involved using a Web interface

11. Project Goals - Business
Due to the nature of the business, the raw material are of extreme high value
i.e. precious metals – platinum
Main goal is to keep scrap levels as low as possible and minimize rework and production cost.
How?
Due to the nature of the business, the raw material are of extreme high value
i.e. precious metals – platinum
Main goal is to keep minimize rework, scrap levels as low as possible and minimize production cost.
How?

12. How to realize these Goals
Need to reduce downtime
Anticipate production problems
Departments to take joint responsibility for critical dependencies
Reduce change-over times
Improve overall coating rate
Need to reduce downtime
Re-act quicker to problems
Anticipate production problems
Departments to take joint responsibility for critical dependencies
i.e. make it more visible in terms of responsibility
Reduce change over time

13. Existing Wonderware install base.
Why Wonderware
Existing Wonderware install base.
InTouch SCADA network of appr I/O
Wonderware Historian 2K5 and Active Factory clients
BASF wanted to utilise their present investment
Scalability of the Wonderware solution

14. Why Wonderware
Information Server from Wonderware (WIS) provided a solution
Good working relationship has been built up with the supplier
Top quality training is provided

15. Project Solution
Solution aimed at making the information more centrally accessible
Control Room environment
Web Clients for managers
Displaying the coating, slurry and operation information
Production Data
Downtime
Machine and process Status
Bringing maintenance, production and process engineering closer in terms of their separate operations

16. Implementation - Prerequisites
First step Involve production and maintenance resources to determine the information needed
Made each person Responsible for the availability of the data by
Training
Do own modifications on the SCADA
Involvement
Determine the information needed,
how to display it,
where to get it from
Responsible
availability of the data by
providing them with training
let them make the changes on the SCADA themselves.
Taking ownership of the system

17. How it was implemented
Installed the Wonderware Information Server (WIS)
Gather data from various systems in the plant
Both Wonderware and other sources.
Control room set up with multiple large LCD displays
Both production and maintenance used.
Build web based reports for management
Project took 3 months
Wonderware Portal was not yet installed
Data was sources from InTouch, LIMS (Oracle DB), a number of MS SQL databases where was logged from InTouch as well as data from the Historian
The control room provides a holistic picture of the complete plant
Accept for the real-time information, reports were built using Reporting Services and published using WIS
From start to finish. The most consuming part was deciding what data we want to see and modifications had to be made to PLC’s, SCADA and the Historian to make it possible. Each plant section was responsible for their own data.

18. Data acquired – Multiple Sources
ACTIVE FACTORY /
WE CLIENTS
LIMS
Oracle DB
SCADA Systems
InTouch
Historian / Information Server
Schematic on Data flow
SLURRY MANUFACTURING
MS SQL Server 2005
COATING LINES
MS SQL Server 2005
CONTROL ROOM

19. Topology Network TCP/IP (LAN) Active Factory Clients SLURRY AREA
CONTROL ROOM
Wonderware Historian
MS SQL Server
Web Portal – Information Server
WIS Clients
Active Factory Clients
SLURRY AREA
InTouch SCADA
Plant PLC’s
MS SQL Server
MIXING AREA
LAB / QA
InTouch SCADA
LIMS – ORACLE DB
Plant PLC’s
Topology
PRODUCTION AREA
InTouch SCADA
Plant PLC’s

20. Control Room Wonderware Information Server (WIS) Clients Multi Views
Trends and Charts
Historian
Average rates of the coating.
Real-time Graphics
InTouch
KPI’s
Downtime Status
Alarm Conditions
Data charting
Table Weaver - Interactive, drill through data tables
Drill-down Reports
Table Weaver
Collaborating Data from different sources

21. Introduction Agenda Project Solution Benefits Considerations Summary
Agenda - Benefits

22. Benefits / Goals Achieved
Initial Goal
Comment
Central Repository of real-time data
Control Room with real-time data display from various system
Capitalize on existing Wonderware installation
No additional cost for software was incurred
Provide value to all plant sections to improve production/maintenance
Factory sections took ownership – previously under utilized SCADA network has become a crucial resource and tool.
Reduce downtime, scrap levels and as a result production cost
Reduction of 2,5 hours downtime per week as a result less scrap and an increase in production
Improve Average Coating Rate
Coating rates have improved – no percentage improvement available yet due to changes in processes. Busy analyzing new average rates.
Initial Goal
End Result
Central repository of real-time data
Control Room with real-time data display from various system
Capitalize on already available Wonderware installation
No additional cost for software was incurred
Let all plant sections utilize the system to improve production/maintenance
Production and maintenance took ownership – previously under utilized SCADA network has become a crucial resource and tool.
Reduce downtime, scrap levels and as a result production cost
Reduction of 2,5 hours downtime per week as a result less scrap and an increase in production

23. Introduction Agenda Project Solution Benefits Considerations Summary
Agenda - Considerations

24. We started by doing training first
Considerations
Infrastructure (PLC network and LAN) was in place which made it easier to gather the data
We started by doing training first
Involving maintenance, production and process engineering made the project run smoother
Infrastructure (PLC network and LAN) was in place which made it easier to gather the data
We started by doing training first
Good decision
Can maintain and make changes ourselves
Involving maintenance, production and process engineering made the project run smoother
Correct information was made available from the beginning

25. Introduction Agenda Project Solution Benefits Considerations Summary
Agenda - Summary

26. In Conclusion
Richard Mangold Service Platform Manager “ The Wonderware package is very broad, the more training and awareness, the more it can be utilized becomes a true asset to the company.” “Attend more sessions, breakfasts and road shows – the benefits are there!”
Richard Mangold
Service Platform Manager
“ The Wonderware package is very broad, the more training and awareness you can get from the distributors, the more it can be utilized to become a true asset to the company.” Attend more sessions, breakfasts and roadshows – the benefits are there!”

27. Thank you for attending
Questions
Thank you for attending
Thank you for attending

28. Graphics Library