1. Site Specification Management Using the RtPM Platform
Tamara Carbaugh
The goal of this presentation is to show how product specification data (stored in ProcessPoint) can provide valuable context to RtPM clients. The talk will first discuss the need for specification management and the powerful change management features in ProcessPoint. We will then show a series of demonstrations to show how this spec data can provide benefits to manufacturing operations and quality personnel.

2. Outline
Industry Challenges
Features
Benefits
Demonstration
Summary

3. Industry Challenges
Product quality and consistency depends on managing lots of data
Formulations, bills of material, manufacturing instructions, quality and process limits
Manufacturers need to produce and report according to specification
Market demands manufacturing agility
Our customers face many challenges related to product management. They must deliver consistent products to their customers regardless of which site made a particular shipment of a product. Delivering high quality products means managing a lot of data – formulations, quality specifications, processing parameters, etc.
It is not enough to make a good quality product – our customers need to be able to prove that they made a good quality product. Using specification data to provide context to real-time manufacturing clients helps manufacturers make product according to quality limits. The same quality limits can be integrated with our reporting tools to automate portions of the certificate of analysis generation.
Our customers need to be able to adapt quickly to new recipes and customer requirements and roll these requirements out to manufacturing lines.

4. The Need for Specification Management
What has been approved?
Do I have the most recent copy of the specs?
Can I see the data differently?
Change Request
Customer Specification Sheets
Without a specification management system that provides change management and version control, many users are left asking themselves these questions:
What has been approved?
Do I have the most recent copy of the specs?
Can I see the data differently? If I create a new copy of the data in the format I need, am I now just creating another document that will need to be updated when spec changes occur?
Do my operators and quality personnel have the same specs that I have?
New Specification Binder
Old Specification Binder

5. The Value of Specification Management
Up to date 
Approved 
On line 
Version management 
Displayed the way I need 
With a specification mangement system, users are assured that their specs are:
Up to date 
Approved 
On line 
Version management 
Displayed the way I need 

6. The Need for Contextual Data
Is the product being made according to customer specifications?
Is that increase good, bad or potentially dangerous?
Without specification context on your real-time manufacturing trends, do the operators know if a change is good, bad or potentially dangerous? How do operators know whether or not they are producing according to quality requirements?

7. The Value of Contextual Data
Customer specs are being met 
Quality standards are being met 
Waste and rework are being minimized 
With contextual specification data, operators are assured that:
Customer specs are being met 
Quality standards are being met 
Waste and rework are being minimized 

8. Integrated Specification Management Drivers
Equipment lines running multiple products
Many product codes to manage
From a Global Chemical Producer’s website: “Note: product specification information is updated daily and may therefore be different from the specifications shown on any individual Certificate of Analysis.”
Controlled change management procedure
Customers have different specs
Corporate quality initiatives
In process facilities where product codes change frequently on manufacturing lines, the ability to integrate specification data with real-time data through the ProcessPoint COM Connector can provide value context data with the assurance that the real-time displays show the latest, approved version of a specification. As product codes change on lines, the PI server can pull the correct processing targets and quality limits from the spec management system.
Specifications are not static documents – they are constantly changing. In businesses that have many product codes to manage with frequent changes to these product codes, a system for change management that allows for integration of the real-time specification data system with the client tools, assuring operations and quality personnel that they are using the correct version of product specifications
Quote from J.T. Baker’s website: taken on March 29/2006.
To retrieve current Product Specifications, enter the 4 digit Product Number and click on the Product Specifications button located below the input boxes. Note: product specification information is updated daily and may therefore be different from the specifications shown on any individual Certificate of Analysis.”
If customers have different quality requirements, a specification management system can allow users to display actual customer specs against real-time manufacturing data.
Recent article in Chemical Processing talked about how Initiatives to make plants leaner and to enable them to run more efficiently i.e. Six Sigma) can only work if the plant is running in a stable manner and if the customer’s specifications are consistently being met. For customers that need to respond to these lean/quality initiatives adhering to quality specs is

9. ProcessPoint Comprehensive product specification database
System of record for specification information
Product properties
Quality limits
Product parts
Manufacturing procedures
Product history
Approval and electronic signoffs
Provides contextual specification data to
Users
RtPM Clients
Other systems
PI stores and controls, in a world class manner, all that has happened. Every time series signal that you choose to capture in PI can be captured, stored forever and displayed in variety of ways using a wide variety of client applications.
The contrast between PI and ProcessPoint is that PI is focused upon what is happening (snapshot) and what has happened (archive) values. ProcessPoint is completely complementary in that it is focused upon the how the process should run. This is call Pre-Process information.
Similarly to PI, for all data that is of interest, there are facilities in ProcessPoint to store this information.
Similarly to PI, there are a variety of ways to distribute this information and most importantly, use it for comparisons to and with PI historical information.

10. ProcessPoint Fit with RtPM
The PI System stores the complete history of what has happened in the process
ProcessPoint stores the specifications that define how the process should run
Like the PI System does for real-time data, ProcessPoint stores the history of spec data forever and allows it to be used in meaningful ways
PI stores historical and snapshot data. ProcessPoint contains the context of how the product should run.
Just as PI does for the manufacturing data, ProcessPoint stores the history of the product specification data. This is done through version management of the specifications.

11. ProcessPoint Features
Change management
Web parts with role based displays
Integration with real-time manufacturing data
Scalability
Before going to the demo, we will briefly talk about a few of the features of ProcessPoint that make it a powerful spec management system
In the previous .avi we showed how easy it is to use the specs as a set of PI tags. These features show that ProcessPoint is more than just an rdb with spec data in it. It has been designed to suit the needs of the Process industries in terms of developing and managing products.

12. Change Management Features
Structured product definitions
Version history with electronic audit trail
Electronic approval plans
ProcessPoint is flexible enough to specify product for a variety of industries, and do so in a structured, unambiguous manner. ProcessPoint does this around a product record that allows the complete specification stored in a single record.
ProcessPoint stores this specification information forever. All versions of the product are stored with a detailed audit trail.
Product changes are rolled out to manufacturing more rapidly through electronic approval plans.
Structured product definitions
Common set of quality, process and customer specifications
Side by side comparisons
Version history with electronic audit trail
What changes were made?
Who made changes?
When were changes made?
Who signed off on the changes?
Are there any comments about why change was made?
Electronic approval plans
Who approved new versions of products?
What items are awaiting my approval?

13. Web Parts Allow access to specifications Role-based displays
Across sites
Across departments
Across geographical business units
Role-based displays
Users see the data they need in the format they want
Robust security model
You define who sees any specifications
ProcessPoint is truly extensible to other sites and departments through the web parts.
Role-based displays give users a view of the data that is important to them and to their job within the organization.
The same flexible security model that is used for the rich client extends to the web parts, assuring that intellectual property is protected – while a select set of information is shared with those who need it.

14. Integration with Manufacturing Data
One set of specifications
Quality, manufacturing, engineering, sales, other departments all looking at same data
Real-time feedback to manufacturing
Increase product quality
Automate creation of reports
Expedite product shipments
Today’s demonstration focuses on the integration of specification data with manufacturing data. We will show that from one source of spec data, we can provide specs to quality, manufacturing and engineering clients.

15. Scalability ProcessPoint is designed for scalability
Security model, search capabilities
Successful installations include:
Single manufacturing line at a site (10 users)
Enterprise-wide system with more than 50,000 raw material and product specifications with over 300 users spread across 10 countries

16. Sample Customer Application
Pulp and Paper customer using PI, ACE, ProcessPoint and the PP COM Connector
Real-time adjustments to recipe blends and other production specifications
Value:
Ability to adjust feedstock to achieve an optimized least cost formulation
Immediate visibility to the cost impact of recipe changes
Loyal OSIsoft customer in the Pulp and Paper industry
Monitor grade run cost and modeling on real-time production.
Software Components: PI, ACE, ProcessPoint, PP COM Connector
Specification data (raw material, product attributes, process parameters) modeled in ProcessPoint
Integrated system is used real-time to facilitate adjustments to recipe blends and other production specifications to achieve a least cost formulation.
Result:
Immediate cost impact of recipe changes
Ability for operations management to adjust recipe blends and other production specifications (real time) to achieve an optimized - least cost formulation. This is achieved through introducing various ratios of “virgin fiber” as opposed to “reclaimed fiber” ingredients.

17. Sample Customer Application
customer using PI, BatchView, Data Entry Grid, AlarmView, SQC, ProcessPoint, PP COM Connector, ProcessBook
Quality and manufacturing specifications from ProcessPoint are integrated with real-time manufacturing data
Value:
Visibility of adherence to manufacturing targets, in an environment with frequent grade changes
Improved quality and grade consistency
Ability to analyze and improve the process through product based alarming and SQC analysis

18. Benefits Improved change management Quicker time to manufacturing
Reduced waste
Reduced product variability
Higher quality and increased customer satisfaction
Ability to analyze and improve manufacturing
ProcessPoint provides value as a standalone spec management system, but when coupled with the real-time performance management system, users can see:
Reduced waste
Reduced product variability
Higher quality and increased customer satisfaction

19. Demonstration Scenario
Pulp and paper example
Quality specifications
i.e. Opacity, Ash, Basis Weight
Process specifications
i.e. Machine Speed, Steam Flow, Material Feed Rates
Specification data used to provide context to real-time manufacturing data
This is a pulp and paper example, but ProcessPoint is very well suited to:
-CPG
- Chemicals
Food
Pharmaceutical
mining/metals
The quality specs represent the end product finished quality specifications
The process specs represent the machine settings used in manfuacturing the product

20. Demo Components ProcessPoint PI ProcessPoint Editor Com Connector
Manually Entered
PI pulls specs
Sensors
Process Specs
Quality Specs
ProcessPoint PI
Alarms
Com Connector
Report Templates h
ProcessBook
AlarmView
Data Entry
Grid
DataLink
SQC
RtReports

21. Product Specifications: ProcessPoint
Demo Description
10 Quality parameters with:
Minimum, Target, Maximum
10 Process parameters with:
URL, UAL, TGT, LAL, LRL
Version management
Electronic audit trail
Value
Capture the data important to your process
ProcessPoint stores the complete product
Powerful change management capabilities
Spec data distributed to users, RtPM clients & other systems

22. This part of the demo shows the search functionality, duplicate and change management features.

23. Process Monitoring: ProcessBook
Demo Description
Real-time process data from PI
Specification context data pulled from ProcessPoint with COM Connector
Snapshot and historical data shown
Limits update automatically when product code changes on equipment
Value
Instant feedback to operator when manufacturing is outside of limits

24. This shows a screen that could be used in a control room to monitor the process.
Except for the horizontal bars that change color when values are in spec (green) and out of spec (red), everything else is BASIC processbook functionality. There is a little bit of VB behind these horizontal bars that looks at the spec tags and the real-time data tags for the color.

25. Respond to Process: AlarmView
Demo Description
Product based SQC Alarms
Alarm limits come from ProcessPoint
Operators can enter reason codes or comments when violations occur
Value
Product based alarming
History of alarm events with reason codes allow for post-production analysis and improvement

26. This is version 2 of AlarmView
This is version 2 of AlarmView. New features in this release include the ability to add comments/reason codes to alarms. These comments are historized and can be analyzed post production.

27. Enter Manual Values: Data Entry Grid
Demo Description
Quality tests are performed on the product and results are manually entered
Specification data from ProcessPoint
Manually entered data inserted into PI
Value
Manual data is stored in PI Archive
Users get immediate feedback when manual data is out of spec

28. There are a few manual data entry products from OSIsoft
There are a few manual data entry products from OSIsoft. This one is very useful for batch or run based data. This is an add in to ProcessBook that has some nice configuration tools in it.
The column on the left shows the grade code, reel code and start/end time. The values below these show the test names. The columns to the right represent individual reels of paper.
The trends at the bottom of the screen are used to show historical data for these quality tests.
Users enter data by placing the cursor in a cell and typing in a value. Right clicking and selecting “commit” sends these values to the PI archive. If an entered value is out of spec, the cell will turn red (color is configurable). Mousing over the cell will show the spec limits.

29. Analysis and Improvement: DataLink
Demo Description
Side by side comparison of key quality and process values
Quality and process specification limits from ProcessPoint
Manufacturing data from PI
Value
Detect out of spec patterns
Link process conditions to finished product quality

30. DataLink is already a widely used tool that has powerful analysis capabilities. This demonstration shows how specification context can be added to datalink for analysis.

31. Process Improvement: Real-time SQC
Demo Description
Real-time SQC charts configured with:
URL spec tag set as upper spec limit
UAL spec tag set as upper control limit
TGT spec tag set as center line
LAL spec tag set as lower control limit
LRL spec tag set as lower specification limit
Value
Statistical calculations performed automatically
Determine:
Do limits reflect operating capabilities?
Can specification limits be tightened?

32. Real-time SQC is an add-in to ProcessBook
Real-time SQC is an add-in to ProcessBook. It is very simple to configure. We set the LRL, LAL, TGT, UAL, URL as the spec limits on the SQC tag. The add-in then does some automatic calculations for us.

33. Certificate of Analysis: RtReports
Demo Description
Report templates stored in PI
PI provides real-time quality data
ProcessPoint provides specification data
Value
Automate generation of Certificate of Analysis
Expedite shipment of finished product

34. This is the new version of RtReports
This is the new version of RtReports. A couple important features about this version:
Comes in standard and compliance editions – compliance edition has workflow/electronic signature capabilities
Both standard and compliance editions now support time based and AF Case based reports as well as batch based reports
First part of the demo is selecting batch based report and then doing a search for the report templates that fit this requirement. Then we do a search for batches in a certain time period on the equipment PM1 (paper machine1). Then a batch is selected to be run against the report template and the result is generated.

35. Demo Summary ProcessPoint adds specification context to RtPM clients
ProcessBook
PI SQC
AlarmView
Data Entry Grid
PI DataLink
RtReports
To learn more about this, visit the demo pod or attend the Wed afternoon class that the training group is conducting on RtPM. (sign up required for the class – not sure when the deadline is)

36. Summary
Drive Operational
Efficiency
Standardized data model and structured environment for controlled change management
All users access the same set of product specifications for process and quality parameters
Accelerate Decision
Making
Provide visibility of specification data to real-time displays and data analysis tools
Enable automated compliance reports
Less time managing specs and more time improving the process
Improve product quality and consistency
Reduce waste and rework
Enable
Performance-Driven
Manufacturing
ProcessPoint provides a standardized data model and structured environment for controlled change management of specification data
The integration of real-time specification data into real-time trends, alarms and displays can provide users with instant visibility into how closely manufacturing is meeting specifications
Existing OSIsoft customers can use ProcessPoint to add product-specific context to their real-time displays