framing quality with pi data - etouches · 2007 - user conference - monterey nwa statistical...
TRANSCRIPT
Presented by
© Copyr igh t 2013 OSIso f t , LLC Pac i f i c A lumin ium, Ke i th S inc la i r and Assoc ia tes .
Framing Quality with PI Data
Chris Noonan
© Copyr igh t 2013 OSIso f t , LLC Pac i f i c A lumin ium, Ke i th S inc la i r and Assoc ia tes .
Agenda
Pacific Aluminium at a Glance (10 min)
Our Journey with OSIsoft (10 min)
Quality Framework (13 min)
Application of the Quality Framework (10 min)
Wrap Up and Questions (2 min)
2
9:45
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Full Version http://www.youtube.com/watch?v=uU_ldmWyoEs
© Copyr igh t 2013 OSIso f t , LLC Pac i f i c A lumin ium, Ke i th S inc la i r and Assoc ia tes .
Pacific Aluminium at a Glance
Our Journey with OSIsoft
Quality Framework
Application of the Quality Framework
Wrap up and Questions
5
9:55
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2000 2001 2002 2003 2004 2005 2006 2007 2008 2009 2010 2011 2012 2013
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2012: PIMS Quality Framework Delivered to NZAS Metal Products
2000 • IS&T Strategy
recognised real time data was being lost and was unable to be analysed
• OEE Project started
2002: OSIsoftSelected
2002: Pilot at Bell Bay Cast House established basic design and principles (PI ProcessBook, PI Batch and PI Module Database)
2003->2004: BSL and NZAS Cast HousedProve design transportable Established a permanent team – RTA and contractors
2003 ->2007 Configurable Data Entry developed.
2005->2007: Carbon plants are reaching the limitations of the technology without the relational capabilities of AF and Event Frames
2007->2008: Overhead cranes - Focus on operational and maintenance data
2000 Rio Tinto buys Comalco
October 2007 Rio Tinto buys Alcan
“Integrated Process Management System” –Sinclair Associates
March 2013 IT Systems Separate
October 2011 Pacific Aluminium Formed
2006 XML / XSL Asset Templates “Standard Objects”
2006 -> Statistical Process Control UI Developed
2005 Migration to PI ACE .NET. Batch Factories and Batch Monitors
2013 Rationalisation and configuration of PIMS calculations
2008 -2011 Global Focus 2011 Regional/ Local Focus
2007 - User Conference -Monterey
NWA Statistical Process Control
2009 PI AF 2.02011 - User Conference –San Francisco
2006 - User Conference –San Francisco
RTA holds Metals and Mining Sig Leadership
2012 Event Frames
2013 Publish Subscribe Events Architecture
Our Journey with OSIsoftStop
Press!
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Tags out of the BoxShow what drives this measure
Show with time context
Reuse on similar plant
Find data for assets easily
Quickly get at Data (if you know the tag name)
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Process Book or Datalink• Link directly to the tag –no abstraction
Historian• Tag (e.g. FURNA_TEMP13_PV”) with time series data from the process
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With an Asset Model
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Process Mimics•Link indirectly to the tag via the alias
Asset Framework•(Furnace A – Roof Temperature)
Historian•Tag (e.g. FURNA_TEMP13_PV”) with time series data from the process
Show what drives this measure and how it is managed
Show with time context
Reuse on similar plant
Find data for assets easily
Quickly get at Data
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BakeOEE
Alarms
Mixer Alarms
Module Database Asset Templates in 2006
XML XSL Module DataBase
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Plant
Green Carbon Former OEE
Bake OEE
Plant Green Carbon Mixer Alarms
OEE Filter
Asset Filtering
10
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Asset Templates in 2013?
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• The “PI Asset Framework (AF)”
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Add a Time Model
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Historian (PI)
Asset Framework
Process Mimics
Event Frames
OEE , BatchShow what drives this measure and how it is managed
Show with time context
Reuse on similar plant
Find data for assets easily
Quickly get at Data
© Copyr igh t 2013 OSIso f t , LLC Pac i f i c A lumin ium, Ke i th S inc la i r and Assoc ia tes .
Framing process data in “Event Frames”
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Add a Quality Framework Model
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Historian (PI)
Asset Framework
ProcessBook
Event Frames
OEE , Batch
Quality Framework
Quality Framework
Presentation Layer
Show what drives this measure and how it is managed
Show with time context
Reuse on similar plant
Find data for assets easily
Quickly get at Data
© Copyr igh t 2013 OSIso f t , LLC, Pac i f i c A lumin ium, Ke i th S inc la i r and Assoc ia tes .
Dimensions
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Quality
People
Time
Assets
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Pacific Aluminium at a Glance
Our Journey with OSIsoft
Quality Framework
Application of the Quality Framework
Wrap up and Questions
16
10:05
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Why Frame Quality?
17
• Desire to see “personalized” information on their screen (not having to drill down through an asset structure”
• Quality Systems are still embedded after 13 years, but need support to lock in business knowledge.
• Fewer people need more information pre-packaged to make the right decisions faster
• Appetite for practical problem solving
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Your First Day on the job and…… A customer complains about the product you are sending them. Where do you look in the asset structure for answers? Which tag?
The California Governor reviews an OSIsoft ProcessBook Display when the California ISO Reported a New High for Peak Power Demand
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Quality Maturity Model
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• Processes at this level that the focus is on continually improving process performance through both incremental and innovative technological changes/improvements.Level 5 - Optimizing
• Processes at this level that, using process metrics, management can effectively control the AS-IS process. In particular, management can identify ways to adjust and adapt the process to particular projects without measurable losses of quality or deviations from specifications. Process Capability is established from this level.
Level 4 - Managed
• Processes at this level that there are sets of defined and documented standard processes established and subject to some degree of improvement over time. These standard processes are in place (i.e., they are the AS-IS processes) and used to establish consistency of process performance across the organization.
Level 3 - Defined
• Some processes are repeatable, possibly with consistent results. Process discipline is unlikely to be rigorous, but where it exists it may help to ensure that existing processes are maintained during times of stress.Level 2 - Repeatable
• Processes are (typically) undocumented and in a state of dynamic change, tending to be driven in an ad hoc, uncontrolled and reactive manner by users or events. This provides a chaotic or unstable environment for the processes.
Level 1 - Initial (Chaotic)
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How do we move up the Maturity Model?
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Understand Cause and Effect (Relationships)
Let the process tell us when not in control or capable
(SQC)
Understand the what the
customer is willing to pay for
(What’s important)
Lock in agreed action plans and accountabilities
(Plan)
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What do Customers Want?
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• My Aeroplane motor doesn’t ceaseOil and Gas
• Electrical losses in my cable are lowMining and Metals
• My toaster doesn’t diePower Generation and Transmission
• My printer doesn’t jamPulp and Paper
• I don’t get sickFood and Beverage
• The side effects are minimalPharmaceuticals
Understand the what the
customer is willing to pay for
(What’s important)
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Relationships
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Understand Cause and Effect (Relationships)
Customer Requirements
Product Properties
Properties at the end of each process
Critical Process Variables
Maintenance and Procedures
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Leveraging the PI SQC TagLet the process tell us when not
in control or capable (SQC)
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Leveraging the PI SQC Tag
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• Leverage Product• Store Control Limits• Store Capability
Limits• Store Comments• Change Aggregation
Methods
Let the process tell us when not
in control or capable (SQC)
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Oil Analysis Response Plan Example
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High copper is found in the oil sample
Two maintainers change out the gearbox, strip it down and prepare to repair it.
Response
Lock in agreed action plans and accountabilities
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Oil Analysis Response Plan Example
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If a response plan was in place for high copper, would the maintainers have changed out the gearbox and not the pump which contained brass?
Lock in agreed action plans and accountabilities
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Locking in Improvement
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Measurement Plan• How will the measurement be taken• Who and How Frequent?
Control Plan• How will the control charts be displayed• Who and How Frequent?
Response Plan• How will we respond in a standard way• Who?
Lock in agreed action plans and accountabilities
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The Quality Framework Model
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Role
Measurement, Control, Response Plan
Person
Organizational Hierarchy
Frequency
Relationship to upstream and
downstream metrics
Measurement
PI Process Data
Customer – Supplier Relationship
Relationship type
Relationship Strength (H,M,L)
Standards
Process changes
Actions
Metric
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Show me all my measures that are not in control
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Role
Measurement, Control, Response Plan
Person
Organizational Hierarchy
Frequency
Relationship to upstream and
downstream metrics
Measurement
PI Process Data
Customer – Supplier Relationship
Relationship type
Relationship Strength (H,M,L)
Standards
Process changes
Actions
Metric
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Show upstream measures
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Role
Measurement, Control, Response Plan
Person
Organizational Hierarchy
Frequency
Relationship to upstream and
downstream metrics
Measurement
PI Process Data
Customer – Supplier Relationship
Relationship type
Relationship Strength (H,M,L)
Standards
Process changes
Actions
Metric
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Compare FurnaceTemperatures
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Role
Measurement, Control, Response Plan
Person
Organizational Hierarchy
Frequency
Relationship to upstream and
downstream metrics
Measurement
PI Process Data
Customer – Supplier Relationship
Relationship type
Relationship Strength (H,M,L)
Standards
Process changes
Actions
Metric
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Compare “Standards”
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What outstanding actions are there for my team?
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Role
Measurement, Control, Response Plan
Person
Organizational Hierarchy
Frequency
Relationship to upstream and
downstream metrics
Measurement
PI Process Data
Customer – Supplier Relationship
Relationship type
Relationship Strength (H,M,L)
Standards
Process changes
Actions
Metric
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Actions
34
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Impact of upstream process changes (Ball Mill)?
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Role
Measurement, Control, Response Plan
Person
Organizational Hierarchy
Frequency
Relationship to upstream and
downstream metrics
Measurement
PI Process Data
Customer – Supplier Relationship
Relationship type
Relationship Strength (H,M,L)
Standards
Process changes
Actions
Metric
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Finding Data
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“…it starts to make sense of the wealth of information that is buried within PIMS.”
“It’s not that the data is not valuable it’s more that the critical few are not presented/displayed in the most helpful way. The Quality Framework would appear to provide a method for solving this issue – presenting data in a helpful way.”
“To the vast majority of people who are not “über-users”, finding your way through mountains of PIMS data to find what you need can be challenging.”
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Standards
Documentation
Accountabilities (who and when)
RelationshipsActions
Process Changes
© Copyr igh t 2013 OSIso f t , LLC Pac i f i c A lumin ium, Ke i th S inc la i r and Assoc ia tes .
Pacific Aluminium at a Glance
Our Journey with OSIsoft
Quality Framework
Application of the Quality Framework
Wrap up
38
10:20
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The Problem – High Scrap
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“All those involved on the billet process scrap reduction project have seen the potential power of the framework and devoted significant time to its construction – primarily as it makes data analysis far more efficient and effectively provides the Control step of the DMAIC process.”
“Controlling Scrap is worth $3,200,000 per annum”
“One of their first challenges has been to stabilise the process and reduce variation. This has required the charting of the CPVs and development of response plans. The Quality Framework has been the ideal solution to achieve both activities.”
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What was required
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Cultural change and belief that reducing variation will reduce costs.
A coach to help change the culture and coach variation reduction
techniquesSupport from a sponsor with a process not “in
control”The Quality Framework
System
Timely, Accurate Data
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Examples
41
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Supporting ISO9001 Certification
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“The work that Chris and Melissa did last week in mapping the process and the codification of the output within the Quality Framework will tick this box very nicely. Once implemented, the Quality Framework should virtually eliminate the need to repeatedly keep documentation current etc. This is a reasonable resource saving (Melissa will thank you for it!!).”
“The key recommendation that the auditor gave was to ditch our traditional quality manual (linked to an older version for the ISO9001 standard) and adopt a layered descriptive “process flow” approach.”
“In effect this changes ISO accreditation from being an “add-on”, with the attendant administrative burdens to keep documentation current, to a valuable training and communication tool that reflects the process and its interdependencies.”
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User Feedback
43
“Placing cycle time data within the Quality Framework will give us the ability to make cycle time reduction decisions efficiently and robustly.”
Instead of using SPC we have substituted it with “have we got a problem or not with this process?” As you can appreciate, we sometimes do not respond when we should, and other times we respond to process noise. We anticipate that the use of SPC on our process metrics will greatly improve the deployment of our scarce resources – only responding to process when it actually tells us something (actioning special cause exceptions and pre-empting out-of-control).
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• Scrap rates continue to drop, the cause and effect is now being locked in to the corporate knowledge.
Solution Results and Benefits
Pacific Aluminium: Framing Quality with PI Data
Business Challenge• High scrap rates in the
Billet plant was costing the business a lot of money
• Pulling PI Data together with a meta data framework enables people to find the right data quickly.
“To the vast majority of people who are not “über-users”, finding your way through mountains of PIMS data to find what you need can be challenging.
It’s not that the data is not valuable it’s more that the critical few are not presented/displayed in the most helpful way. The Quality Framework provides a method for solving this issue – presenting data in a helpful way.”
44
10:30
© Copyr igh t 2013 OSIso f t , LLC Pac i f i c A lumin ium, Ke i th S inc la i r and Assoc ia tes .
Pacific Aluminium at a Glance
Our Journey with OSIsoft
Quality Framework
Application of the Quality Framework
Wrap up and Questions
45
Questions?
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Chris [email protected] Value Realisation & Bus. Intelligence, Production Systems Pacific Aluminium
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Keith Sinclair
Pacific Aluminium at a Glance
Our Journey with OSIsoft
Quality Framework
Application of the Quality Framework
Wrap up and Questions
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Sinclair Associates