Performance Management for the Cement Industry

7/30/2019 Performance Management for the Cement Industry

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IndustrialIT: Performance Management

for the Cement Industry

InformIT Knowledge Manager


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Knowledge Manager:

Maximizes the

economic perfor-

mance of your

assets

Enables you to

reach environ-

mental, produc-

tion and quality

goals

Supports the

achievement of

quality manage-

ment by inte-

grating process,

production and

quality informa-

tion

Supports defined

work processes

and ensures man-

power efficiency

by delivering rele-

vant operation

information for

improved decisi-

on making

Process Control

Profitability

Best Practice

Real-Time Performance MonitoringExperience Knowledge

Process Data Management

Production Information

Management

Production

Accounting

SAP

IntegrationLIMS

Raw Data

Statistical Production

Analysis

Excel

Add inKnowledge

Manager

Effective production management

If you have the specific information you need at

the right time and the right place in the right for-

mat, your decisions will be more goal oriented, and

you will be able to optimize processes and incre-

ase productivity. With Knowledge Manager, part

of ABB's InformIT application suite, you have the

solution and advanced tools you need to facilitate

the collection, organization and distribution of pro-

duction and quality information throughout your

plant organization.

Saving you money

Knowledge Manager's flat learning curve saves you

instruction and implementation time. Research into

information systems technology, software program-

ming or interfacing is unnecessary. For example,

the industry-specific applications are available as

a set of ready built but configurable objects, enab-ling you to capitalize on the expertise of others

who have already developed equivalent solutions.

Quite simply, you enter the learning curve at a

much higher level. The time needed to produce a

working solution is much shorter, involving less

risk and less lead-time before on-site knowledge

management begins. You decide how much of the

solution development you wish to do in-house

and how much assistance you would like ABB to

provide.

Modular design

The core of Knowledge Manager comprises all

the functions and components needed for indus-

try specific process and quality data warehousing

and focused information presentation. Knowledge

Manager can be adapted and expanded to meet

each company's specific requirements, and can

incorporate up to several hundred users in order to

keep pace with growing demand.

InformIT Knowledge Manager

Produce quality products more effectively

All production

knowledge at your

fingertips. You

need easy access

to timely, accurate,

reliable information

in order to enhance

enterprise-wide

productivity.

Real-time automated key performance

indicators (KPIs) to support decision-

making, enabling best-in-class manufactu-

ring, saving up to US$300k per year

Emission tracking and compliance certifi-

cates, saving up to 2 people weeks every

month

2 people weeks saved every month

through advanced material balancing

tools

US$200k saving through SAP integration

and consultancy

Quality optimization, tracking and

management, saving up to 2 people years

per year

Savings of up to US$500k in everyinstallation:

SAP

DispatchAutomation

Solution

AutoLab

Quality

Robotics

Microsoft Excel


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Production Information Management

A powerfulaid to help monitor plant performance

InformIT Knowledge Manager Production Informa-

tion Management drastically simplifies production

management, covering production related func-

tions like:

production tracking and reporting

process operations monitoring and reporting

material storage management, and

energy and emission reporting.

Identifying the influences that process parameters

have on product quality, production capacity, ener-

gy consumption and emission levels is now easier

than ever. Powerful analysis tools are available at

the click of a mouse button. After all, successful

process information is key to your plant operation.

The Knowledge Manager production management

functionality includes running plant overview and

specific calculating and reporting capabilities for

production, material storage and emissions.The key to production planning is the online

access to information without delays. Knowledge

Manager provides reliable reports on the plant pro-

duction situation: product stocks, capacities of pro-

cess equipment, availability, etc. Better utilization

of energy, equipment, inventories and capacities

can be expected.

Process operation support helps process managers

identify the influences that process parameters

have on product quality, production capacity, etc.

It combines production related data, process varia-

bility, energy indexes, run-time quality parameters,

etc. in comprehensive process operation reports.

Connectivity to ERP systems (SAP, BAAN, People-

Soft, etc.) is nowadays an essential tool to bring

production data from floor level to enterprise

management level. Knowledge Manager serves

here as the information broker between the real-

time control and production environment and the

transactional based ERP systems.

With Knowledge Manager, production and

process managers become empowered know-

ledge workers.

Process analysis

Process visualization

Operation reporting

Charts & trending

Production data analysis and reporting

Production management support

Key Performance Indicators

Energy reporting

Material and stock reporting

Environmental reporting

Performance Monitoring

Fast and informed

decisions:

Increased pro-

duction through

best-in-class

work practices,

greater focus

and deeper

understanding

Real-time

manufacturing

performance

and target moni-

toring for conti-

nuous improve-

ment


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Production Information Management

Minimize plant equipment down-time

Is downtime earning you money? Most definitely

not. Reducing downtime and keeping up produc-

tion capacity is vital for any production plant. And

correct information is the key. The Knowledge

Manager Downtime Management and Mainte-

nance Support solution ensures you know for cer-

tain what your most costly problems are, taking

the guesswork out of maintenance by integrating

facilities for easy identification of failing equip-

ment. Pareto analysis is used to find out the real

and most costly weak points in the production

process and provides support for forecasting the

next maintenance event.

Identification of failing equipment is based on

event and alarm statistics. Results are issued dai-

ly/weekly in e.g. TOP TEN forms. Maintenance

events of specific process equipment are forecas-

ted by using equipment running hours, produc-tion totals, cumulative energy utilization, etc.

Pareto analysis is based on configurable causes

based on a plant definable fishbone diagram. Reli-

able statistical information on downtime causes

is the basis for corrective action. The information

is essential for justification of capital expenditure,

personnel training, etc.

Direct integration of information into your ERP

(Enterprise Resource Planning) system is an

obvious advantage. Transferring stop logs, running

hours, downtime statistics, etc. to SAP's PM and PP

module, is a matter of plug and play. It eliminates

the work of the manual input through the SAP GUI.

Although automatic, it allows for validation, manu-

al correction and approval by the maintenance and

production manager before transfer. Through inter-

faces like these, we protect your long-term invest-

ments by making use of industry standards.

Maintenance forecasting support

Root cause analysis

Pareto analysis on production stops and failures

Production stop reporting

Low rate production reporting

Key performance indicators

Running hours administration

Alarm and event recording and analysis

Downtime Management and Maintenance Support

Take the guess

work out of

maintenance:

Identify real

and costly

weakpoints

in production

process

Forecast the

next mainte-

nance event

Improve plant

equipment

availability and

efficiency


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Cement Production Accounting

Reconcile production results quickly

Within the cement industry, production accounting

activities are usually focused on the month-end

closing and on the day-to-day administration of

materials, consumption and efficiency. The regular

challenge of making production results coherent

and consistent is drastically simplified and sped

up with Knowledge Manager's Cement Production

Accountant.

In the Knowledge Manager environment, all the

required data is automatically collected from the

different subsystems on the plant such as process

control systems, the dispatch system, sales admi-

nistration and so on. The data is then rolled-up

and calculated into a one-page overview. Detected

discrepancies between figures are highlighted.

You can then drill down into each of the results to

consult the data hierarchy, the calculations and the

input data that produced the particular result. Datacan be adjusted and the new results previewed.

Knowledge Manager automatically takes care

of the reconciliation of related data so that the

database remains consistent. Any further reports

will show figures that are consistent with pre-

vious reports. For systematic and re-occurring

adjustments, variable factors can be applied on

the source data. When the factors are adjusted

systematically, a learning effect is achieved and

the relative discrepancies will minimize over time.

Historical analysis of the correction factor schemes

provides valuable information to minimize accoun-

ting efforts.

Further improvement is achieved in the automated

day-to-day administration of materials. By using

advanced stock tracking mechanisms, available

data is automatically calculated. The latest and best

possible estimates of non-instrumented storage

locations such as stockpiles and bulk silos are pro-vided.

Production data

inevitably require

balancing and

reconcilation

before reporting.

Production accounting overviews

Material balancing

Data drill down / result transparency

Advanced stock tracking

Dispatch connectivity

ERP connectivity

Manual/automatic data correction / adjustment

Historical correction schemes with learning

capability

Data reconciliation

Cement Production Accountant


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Excel Add-In

Ad hoc reporting quickly

Sourcing the right information from everywhere,

manually typing it in, transferring it to the right for-

mat, etc. for a report that had to be ready

yesterday? The Knowledge Manager Excel Add-In

makes user specific ad hoc reporting much easier.

You can run queries directly from the Excel spreads-

heet without the need to write SQL queries. You

simply select the data required. With underlying

direct web queries, the data is retrieved from one or

more servers simultaneously. Thus the production

information is available for further processing and

formatting with standard Excel functions. Important-

ly, this bi-directional link can easily be used for bulk

data correction in Knowledge Manager.

Retrieval of all available data to Excel

Bi-directional for bulk data correction

Multiple retrievals per spreadsheet

Retrieve data from multiple servers

Easy pick & choose

Shortcut buttons for common selections

No SQL language required

Store selection for reuse

Excel Add In

Having an im-

promtu meeting?

Use extensive

Excel tools to

provide:

Additional KPIs

Performance

reviews

Budget plans

Cement quality

reviews and

forecasting

Process models

and studies

Information

available in Excel


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How is the business performing?

ManagementOperationsProduction

SalesMaintenance

Quality

How is the plant performing?

Production,

Material and Energy

Consumption

Production,

Orders,

Deliveries,

Goods Received

MM/SD PP-PI PM

SAP

Knowledge Manager

Production

Information

Manager

Production

AccountingLIMS

Process Data Management

Control System LaboratoryManual Entries

Knowledge Manager SAP Connector

Extend your knowledge by integration with your

SAP System

The Knowledge Manager SAP Connector extends

the reach of Knowledge Manager into enterprise

applications by supporting the direct interaction

between the manufacturing processes with SAP

ERP software.

Using this connector, the manufacturing informati-

on integrates with the SAP; and the business infor-

mation from SAP integrates to the manufacturing

environment in a smooth and accurate way.

All the methods required for connecting to SAP and

transferring the manufacturing information are fun-

damental to the Knowledge Manager SAP Connector.

The engineering and configuration of the SAP con-

nector is done through the Knowledge Manager

Application Developer Toolkit, i.e. the same tools

and methods used for report configuration are

used to configure the SAP Connectors. No specific

knowledge of the SAP internals, or SAP interface

technologies, and most importantly no knowledge

of software development is required to use or

configure the connectors. On SAP no specific cus-

tomization is required in most of the modules; the

Knowledge Manager SAP Connector replaces the

re-entering of data with electronic data transfer.

Manufacturing information integrated in SAP

Business information integrated in KM

No specific knowledge of SAP programming

required

Engineering and configuration through KM toolkit

Online exchange of information between

SAP and KM

SAP PP-PI connector

SAP PM connetor

SAP MM/SD connector

SAP Interface

SAP Interface

provides:

Online integrati-

on of manufac-

turing in overall

business process

Packed solution

based on stan-

dard methods

Short implemen-

tation time

Easy to

maintain, no

SAP experts

required

Applications:

Production

costing

Production

planing

Material

management

Plant

maintenance

Extensive KPIs


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Laboratory Information Management System

The coordination

of process, pro-

duction and labo-

ratory tasks makes

LIMS a reliable

backbone for the

day-to-day run-

ning of a profess-

ional laboratory:

Benefit from

unique, seem-

less and full

integration of

information

Visualize and

better under-

stand the relat-

ionship between

process conditi-ons and quality

results

The Knowledge

Manager LIMS

is designed to

manage process

quality informa-

tion according

to proven lab

practices.

Integrate laboratory management with

enterprise-wide production

InformIT Knowledge Manager LIMS covers all

laboratory tasks for the entire process and issues

compliance certificates. Naturally it's fully integra-

ted with enterprise-wide process and production

monitoring, downtime support and maintenance

management.

LIMS provides advanced means of documenting

quality information and makes it easily accessible

in a transparent way. It provides operations with

timely quality information on the process, thus

increasing actionable knowledge. Knowledge

Manager LIMS provides the foundation for direct

process management and process quality control

on a day-to-day basis. It is designed to enhance

process improvements and to provide a firm basis

for your further production.

Included are functions such as automatic and

manual data acquisition, data validation, data con-

solidation, long-term storage, calculations, sample

logging procedures, sample status reports, work

lists, standard and compliance reporting features,

easy-to-use trending and graphing plus options for

Excel and statistical analysis applications.

Automatic or manual sample registration

Sample scheduling / worklist

Manual entry forms

Sample status list

Sample survey sheet

Analysis / test reports

Quality reports

Color-coded outliers

Compliance reports

Graphical presentations and charts

LIMS


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Statistical Production Analysis

Correct product quality during production

Statistical Process Control (SPC) information enab-

les operators to compensate for or to eliminate

causes before out-of-specification product is pro-

duced. In InformIT Knowledge Manager Statistical

Production Analysis, the trend functions X Chart,

EWMA chart and CUSUM chart have been selected

to match manufacturing process specific require-

ments. The X-Y graphs provide the facility to plot

two variables against each other to see the possib-

le correlation between them with automatic com-

pensation of time delay. Histograms allow for rea-

dable statistics of run-time quality measurements.

In SPC, the quality is emphasized as a process

characteristic. If the process is controlled and

improved, product quality will be maximized auto-

matically. Therefore, product specifications are

normally left out of quality improvement activities

until the process has first been optimized. Once theprocess has been stabilized, product specifications

are compared to process control limits to determine

if the process is capable of producing the product

to those specifications.

Statistical process control charts contribute

to process and quality improvement:

They provide a picture of the condition of the

process and the improvement of the quality

over time;

They provide information for correction of

causes and for improvement of the process;

They indicate the process capability what it is

actually capable of doing during attributable

cause correction and process improvement acti-

vities.

X-charts (Shewhart)

EWMA charts

CUSUM charts

Histograms

X-Y charts

Statistical Production Analysis

Statistical Pro-

duction Analysis

provides powerful

tools to:

Effectively

monitor quality

related process

variables

Verify if the

variables are

randomly scat-

tered around

the mean and

normally distri-

buted

Detect changes

in variability

and determinechanges in the

process average

early to pre-

vent process

from becoming

unstable

CUSUM, or CUmu-

lative SUM, chart,

used for deviation

control, with the

V mask dynamically

plotted.


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The InformIT

Knowledge Manager

offers intranet

solutions that are

tailored to meet

your specific

requirements.

Thin Clients

Database

and

Application

Server

Data

Collector

Viewer

(Web Browser)Viewer

(Web Browser)Viewer

(Web Browser)

Database

Web Server

Data Buffer Data Buffer Data Buffer

ABB ProcessConnections

Third PartyConnections

LabConnections

Server and User

Application

BusinessObjects ApplicationServer

System Architecture

Knowledge Manager architecture: maximum

information availability

Knowledge Manager is built on the new generation

of technologies. It offers open intranet solutions

for the acquisition and distribution of plant infor-

mation. Knowledge Manager is based on industry

standards, ranging from the hardware and operating

system (Windows 200x) to the database manage-

ment (RDBMS). Desktop functions using the familiar

Windows environment and internet standards such

as HTML and HTTP are provided. The software has

been developed to support a component structure,

and its service oriented architecture (SOA) is based

on a model consisting of a Data Collector node,

Application and Database Server, and a Thin Client.

The Data Collector gathers live data from different

sources and stores it in the local data buffer. It

uses various protocols, including OPC, to com-

municate with ABB and other vendors control

and PLC systems, laboratory analyzers and ERPSystems.

The Application Server, which is where the busi-

ness logic is located, is a software component

responsible for all server and user applications.

It provides services such as data integration and

consolidation, presentation of information, user

authorization and client access management.

The repository for the historical information and

process-based knowledge is the process quality data

warehouse managed by the Database Server. Data

can easily be kept online for years without archiving.

Server hardware performance and storage space is

the only restriction for the number and the lifetime

of data.

The only software that needs to be installed on

client computers is a web browser. Using this Thin

Client technology, it is possible to analyze and

review the collected information from various per-

spectives, generate focused reports to aid manage-

ment with informed decision-making, and discovernew opportunities by exploring historical and cur-

rent process and quality information.

The InformIT

Knowledge

Manager

web-based user

interface brings

all server func-

tions to the desk-

top of the mana-

ger. It provides

comprehensive

and easy to use

graphical tools

based on HTML

technology.


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Application Developer Toolkit

Since ABB is well aware that each customer places

his own special demands on data evaluation and

the acquisition of information, InformIT Knowledge

Manager provides a range of easy-to-use configura-

tion tools.

The Application Developer Toolkit is a graphi-

cal and menu driven configuration tool used to

configure process tags, logs, trends, templates

and reports using simple drag & drop editing. For

example, a user can create and modify templates

for intranet documents, reports or graphics from

a comprehensive library of pre-built business

objects. Using this all in one toolkit, a user can cre-

ate and customize displays, reports, trends, manual

entry forms, survey sheets, etc. and make them

available for other users.

On the Thin Client, the user can navigate in an

intranet, select and view documents, reports and

graphics, or even make manual entries or modify

personal reports using a standard web browser.

Run time viewing of configurations, as well as

import, export and comparison of configurations

are standard features for authorized users. Business

objects for user authorization, user management,

status monitoring, data retrieval, data processing,

configuration handling, consistency checking and

enforcement, etc. are also standard. Moreover, the

Knowledge Manager Application Developer Tool-

kit embeds various scripting tools for additional

complex processing, treatment of data and advan-

ced templates and reports.

The system soft-

ware, toolkit and a

web browser allow

the user to imme-

diately start using

the features of the

InformIT Know-

ledge Manager to

its full extent.

Flexibility

is the key:

No specialist

programming

or web develop-

ment knowledge

required

Toolbox with

pre-configured

elements

Drag & Drop

Copy & Paste

Full system con-

figuration setup

and management

System customi-

zation can

be continued

by customer


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ABB Switzerland LtdCH-5405 Baden-DttwilSwitzerlandPhone: +41 (0)58 586 84 44Fax: +41 (0)58 586 73 33E-Mail: [email protected]/cement 3B

HS128037ZABEO1RevA(07.05.1000Po

mcany's)

ABB InformIT Knowledge Manager

InformIT Knowledge Manager is a web-based process informa-

tion management engine based on the 5R principle:

Relevant information is provided at the Right time, at the Right

place, in the Right form, and to the Right people.

More than 400 installations worldwide are using ABB

knowledge-based solutions for information management and

process optimization. As a world leader in process specific

collaborative production management ABB is continually

developing cutting-edge technology.

Performance Management for the Cement Industry

Documents