1. Global PI System Dow Corning Corporation Doug Loose Global Process Information Manager Dow Corning Profile SPC usdcchd3@ibmmail.com

2. Introduction n Dean Brown - PI System Administrator n Al McInally - Sr. Manufacturing Engineer

3. PROFILE STATISTICAL PROCESS CONTROL n n The Profile SPC real-time engine extends the power of statistical process control to BATCH processes. n n Instead of comparing values of a variable which should be held constant, such as product test data, Profile SPC determines the process parameter profiles versus time into the batch.

4. PROFILE STATISTICAL PROCESS CONTROL(Continued) n n This yields guidelines (a center line and upper and lower control limits that are a function of time into the batch). n n This allows many capabilities: Production personnel can use this to assure that critical parameters are within their SPC profiles, i.e. they are normal batches.

5. PROFILE STATISTICAL PROCESS CONTROL(Continued) n n It “sees” problems which can’t be seen by the usual process monitoring tools. n n It allows mistakes to be corrected before a product is ruined. n n The method employs Deming’s methods REAL TIME to processes and is visual and intuitive.

6. Dow Corning Profile SPC n n Characterization of Current Systems n n Benefits

7. Process Characteristics n n Single recipe batch operations u u Batch times from 8 hours to 2 days to 3 weeks n n Classic continuous distillation columns n n Common feed systems

8. Midland Plant - Process Control System Network PCU5PCU6 PCU1 PCU2 DCU3DCU3 DCU3DCU3 PCU4 DCU1DCU1 DCU1DCU1 ENG LOCDCTDCTDCTDCTDCTDCTDCTDCT DOC GDU DCU2DCU2 DCU2DCU2 DCTDCT PCU3 DCT * Four Separate Display Highways * Redundant Process Highways * Five Control Rooms * Eleven Process Buildings DMC1XDC1XDC2 XDC3 Bridge Plant LAN PCU1 ENG DCT PINet Node

10. Benefits n n Provides in depth process analysis of process variables n n Reduce Quality testing- parametric acceptance n n Reduce Cycle-time

11. Activate/Deactivate SPC Groups Sybase ServerSybase Server PI ServerPI Server Perform SPC on running SPC groups Retrieve Configuration Updates Generate Status File PSPC.EXE Previous run lot # & start times (on activation) New run end time (on deactivation) New run start time & lot # (on activation) Sample trigger tags for all SPC groups PSPC_STATUS.TXT Main processing Loop Raw tag values for previous runs @ N minutes into the run Control limits calc’d @ N mintues into previous run Resultant tag values for current run @ N minutes into the run Control limits calc’d @ N minutes into current run (to be used on next run) New, modified or deleted buildings, SPC groups or points Resultant tags to be created Record status updates & deletes

12. Interested Clients n I would like to re-iterate that Dow Corning is working with OSI to have Profile SPC incorporated into OSI’s SQC package in a future release. We would like to encourage anyone that is interested in this concept to pass this on to Mark Hughes at OSI.

13. Profile SPC Administrator And The User PI System Administrator Dean E. Brown

14. How Does It Work? n Opening Screen n LogIn To SyBase (MS SQL in future versions) n Setting Up A Building n Setting Up An SPC Group for the Building n Requires a Trigger Tag (From 0 to 1) n Setting Up SPC “Resultants” to be Analyzed n A Process on the PI HomeNode does it’s work. n ProcessBook is the Tool for Viewing the Resultants n History Can Be Changed

15. Opening Screen

16. LogIn To SyBase (MS SQL in future versions)

17. Setting Up A Building Building/Area

18. Setting Up An SPC Group for the Building SPC Group Definitions

19. Requires a Trigger Tag (From 0 to 1) Trigger Tag Is A Key

20. Setting Up SPC “Resultants” to be Analyzed Specific Process Tags

21. A Process on the PI HomeNode does it’s work. 0 - 1 - 0

22. ProcessBook is the Tool for Viewing the Resultants No Alarm Over Range Over Center

23. History Can Be Changed

24. Now Users Make Product in a Consistent Fashion

25. Profile S P C Al McInally Dow Corning Corp.

31. Windows Into Processes SQC (after the fact) Profile RTSPC real time (RT) Mass Bal SPC (RT) Cyc.Time SPC (RT) Energy Bal SPC (RT) On line GC (RT) At line data (RT) ?????????? process SPC on continuous process parameters (RT) RT stands for real time

35. V 1 2 3

36. Batch 1

37. Batch 2

38. Batch 3

39. Product A Product B Product C Prod. D Prod. E Product F Prod. G

45. Profile S P C Al McInally Dow Corning Corp.

46. Interested n I would like to re-iterate that Dow Corning is working with OSI to have Profile SPC incorporated into OSI’s SQC package in a future release. We would like to encourage anyone that is interested in this concept to pass this on to Mark Hughes at OSI.