Click to edit Master title style
Overcoming Logistical Challenges
with Collaborative Technologies
OSIsoft Regional Seminar
San Jose, Costa Rica
June 29, 2010
Curt Hertler OSIsoft, LLC
curt@osisoft.com
Empowering Business in Real Time.
© Copyright 2010, OSIsoft LLC All rights Reserved.
Click
to edit Logistical
Master title
style
Overcoming
Challenges
with
Collaborative Technologies
2
•
Traditionally, computerized systems have been focused on automating
calculations, operations, and work flow processes.
•
Automation is an effort to minimize the use of existing human resources.
•
Emerging computer technologies are focused on access to integrated
information, anywhere. Technologies like web-based portals, virtual
presence, and business intelligence tools enable collaboration, allowing
organizations to address challenges in new ways.
•
Collaboration is an effort to maximize the use of existing human resources.
•
Real-time information is essential to fuel the collaborative engine by
enabling awareness and supporting continuous improvement efforts.
•
Distinctive companies extending the value of their existing information
systems by elevating them to provide a real-time information
infrastructure for articulating objectives transparently and delivering
opportunity throughout the enterprise.
Empowering Business in Real Time.
© Copyright 2010, OSIsoft LLC All rights Reserved.
Click to edit Master title style
Overview
• Enabling Awareness: The Value of Real–Time
• Delivering Opportunity: The Need for Infrastructure
• Overcoming the Challenge: Performance Intelligence
• Collaborating to Improve: The Real-Time Infrastructure in Action
3
Empowering Business in Real Time.
© Copyright 2010, OSIsoft LLC All rights Reserved.
Click to edit Master title style
Enabling Awareness
The Value of Real-Time
4
Empowering Business in Real Time.
© Copyright 2010, OSIsoft LLC All rights Reserved.
Click to edit Master title style
The Value of Real Time
Assessment of Condition
Forecast
Electrocardiogram
• Statement of “goodness”
• Actionable
• Critical
5
Empowering Business in Real Time.
© Copyright 2010, OSIsoft LLC All rights Reserved.
Click to edit Master title style
The Value of Real Time
Creation of Opportunity
Online Financial Market Price Quotations
• Accessible
• Responsive
• Tactical
6
Empowering Business in Real Time.
© Copyright 2010, OSIsoft LLC All rights Reserved.
Click to edit Master title style
The Value of Real Time
Evidence of Change
Climate Change Data
• Convincing
• Intuitive
• Impactful
7
Empowering Business in Real Time.
© Copyright 2010, OSIsoft LLC All rights Reserved.
Click to edit Master title style
The Value of Real Time
Fundamental Principle
Fuel flow spikes discovered costing $93,000 / year.
Wasted Fuel Gas
8
Empowering Business in Real Time.
© Copyright 2010, OSIsoft LLC All rights Reserved.
Click to edit Master title style
The Value of Real Time
Another Opportunity – Continuous Improvement
TARGET FUEL
FLOW
9
Empowering Business in Real Time.
© Copyright 2010, OSIsoft LLC All rights Reserved.
Click to edit Master title style
The Challenge of Real Time
Capturing opportunities requires the right people.
10
Empowering Business in Real Time.
© Copyright 2010, OSIsoft LLC All rights Reserved.
Click to edit Master title style
Delivering Opportunity
The Need for Infrastructure
11
Empowering Business in Real Time.
© Copyright 2010, OSIsoft LLC All rights Reserved.
Click to edit Master title style
Infrastructure: Characteristics and Expectations
Real-Time Infrastructure Delivers Opportunities
Electrical Power
Transportation
12
Communications
Music
Empowering Business in Real Time.
•
Valuable – delivers a recognized
benefit
•
Reliable and Secure – always
available, safe and trusted
•
Accessible – adaptable to innovation,
easy to use
•
Contextual - organized to be
effective, efficient, and extendable
•
Sustainable – must be able to last and
adapt to change
© Copyright 2010, OSIsoft LLC All rights Reserved.
Click to edit Master title style
Reliable and Secure Architecture
Full redundancy with Microsoft Security Model.
System
Management
Tools
Clients: ProcessBook, DataLink, BatchView, RtWebParts,
Custom Application…
AppServers: AF, RtBLS, RtReports, ACE
PI SDK
Discovery, Failover, Failback, Load Distribution Services
API
Buffering
PI Collective
Secondary
PI Server
Configuration
Changes
Primary
PI Server
API Buffering
Services
PI Interfaces
13
Empowering Business in Real Time.
Failover
Mechanisms
Configuration
Secondary
Changes
PI Server(s)
API Buffering
Services
PI Interfaces
© Copyright 2010, OSIsoft LLC All rights Reserved.
Click to edit Master title style
Accessible by Expected Standards
• Interfacing with over 400 different automation sources
• Compliance with Industry Standards – OPC UA, PRODML, XML
• Query-based Access, OLEDB
• Integration with Microsoft Office Tools – Excel, VBA
• Integration with Microsoft and SAP Web Prortals
• Supports Application Development- OSIsoft vCampus
14
Empowering Business in Real Time.
© Copyright 2010, OSIsoft LLC All rights Reserved.
Click to edit Master title style
Accessible by Users
Process Context
Graphics
Analytical Context
Spreadsheets and Reports
Performance Context
Process Calculations
15
Empowering Business in Real Time.
© Copyright 2010, OSIsoft LLC All rights Reserved.
Click to edit Master title style
Contextual by Asset for Efficient Extension
16
Empowering Business in Real Time.
© Copyright 2010, OSIsoft LLC All rights Reserved.
Click to edit Master title style
Contextual for Information Integration
Asset Context
Real Time Data
Relational Data
Asset elements derived from a common
template for each equipment type
Formulas
17
Empowering Business in Real Time.
User Defined
© Copyright 2010, OSIsoft LLC All rights Reserved.
Click to edit Master title style
Contextual for Users and Applications
18
Empowering Business in Real Time.
© Copyright 2010, OSIsoft LLC All rights Reserved.
Click to edit Master title style
Overcoming the Challenge
Performance Intelligence
19
Empowering Business in Real Time.
© Copyright 2010, OSIsoft LLC All rights Reserved.
Click to edit Master title style
Collaboration Driven by Transparent Accountability
Accountability of
Manufacturing
Objectives
Articulation of
Performance
Rules
20
Benchmarking
Performance
Against
Objectives
Empowering Business in Real Time.
© Copyright 2010, OSIsoft LLC All rights Reserved.
Click to edit Master title style
Organizational Presentation of Real-time Opportunities
PI WebParts 2010 for Microsoft SharePoint 2007 or SAP Enterprise Portal
21
Empowering Business in Real Time.
© Copyright 2010, OSIsoft LLC All rights Reserved.
Click to edit Master title style
Event-based Notification of Real-time Opportunities
PI Notifications (PI System 2010)
Integration
Email
with with
links
Virtual
relevant
Prescience
information
Technology
22
Empowering Business in Real Time.
© Copyright 2010, OSIsoft LLC All rights Reserved.
Click to edit Master title style
Democratized Business Intelligence
Microsoft BI Vision and Strategy
Improving organizations by
providing business insights to
all employees leading to better,
faster, and more
relevant decisions
 Delivered through a familiar environment
 Integrated into business productivity infrastructure
 Built on a trusted and extensible platform
23
Empowering Business in Real Time.
© Copyright 2010, OSIsoft LLC All rights Reserved.
Click to edit Master title style
Introducing PowerPivot for Excel
Empowering the End User
• Enable users to perform selfservice analysis and intuitively
build their own BI solutions
• Allow users to interactively
explore and perform calculations
on large data sets
• Integrate data from multiple
sources
• Minimize dependence on IT
support
24
Empowering Business in Real Time.
© Copyright 2010, OSIsoft LLC All rights Reserved.
Click to edit Master title style
New Performance Intelligence Tools
Microsoft Excel 2010 with PowerPivot for Data Cube Analysis
25
Empowering Business in Real Time.
© Copyright 2010, OSIsoft LLC All rights Reserved.
Click to edit Master title style
Self-service BI Toolkit for the PI System
• Dimensions and Facts
•
PI Asset Framework (PI System 2010)
• Datasets for BI Data Extraction
•
PI OLEDB Enterprise 2010 (PI for Office 2010)
• Desktop Analysis and Cube Configuration
•
Microsoft PowerPivot for Excel 2010
• Enterprise Accountability
26
•
Microsoft PowerPivot for SharePoint 2010
•
Microsoft SharePoint 2010
•
Microsoft SQL Server 2008 R2
•
Microsoft Office Communication Server 2007 R2
•
PI Notifications (PI System 2010)
Empowering Business in Real Time.
© Copyright 2010, OSIsoft LLC All rights Reserved.
Click to edit Master title style
Collaborating to Improve
The Real-Time Infrastructure in Action
27
Empowering Business in Real Time.
© Copyright 2010, OSIsoft LLC All rights Reserved.
Click to edit Master title style
Enterprise Integration of
Operational Data from
Wind Farms
John Mostek, O&M Engineer
John Deere Renewables
OSIsoft 2010 User’s Conference
28
Empowering Business in Real Time.
© Copyright 2010, OSIsoft LLC All rights Reserved.
Click to edit Master title style
Project Locations
Operating
29
Commissioning
Value now. Value over time.
Construction
Operations Center
© Copyright 2010, OSIsoft LLC All rights Reserved.
Click to edit Master title style
Enterprise Management System
PI is the foundation on which our EMS is built, and is the
basis for dashboards monitored in our Operations
Center
30
Value now. Value over time.
© Copyright 2010, OSIsoft LLC All rights Reserved.
Click to edit Master title style
Dashboards
SharePoint portal environment on intranet, using PI WebParts
Time controls
Aggregation controls
(AF / MDB hierarchy)
31
Value now. Value over time.
© Copyright 2010, OSIsoft LLC All rights Reserved.
Click to edit Master title style
Real-time Status Displays
PI ProcessBook rich client application
32
Value now. Value over time.
© Copyright 2010, OSIsoft LLC All rights Reserved.
Click to edit Master title style
Geospatial Context
Customized code to overlay real-time PI data in the Google
Earth environment
33
Value now. Value over time.
© Copyright 2010, OSIsoft LLC All rights Reserved.
Click to edit Master title style
Production Forecasting
Web services with PI data queries, served up in Business
Objects using Flash
34
Value now. Value over time.
© Copyright 2010, OSIsoft LLC All rights Reserved.
Click to edit Master title style
Alarms and Notifications
35
Value now. Value over time.
© Copyright 2010, OSIsoft LLC All rights Reserved.
Click to edit Master title style
Benefits
• 77% improvement across our fleet in Energy Capture
performance metric within first 6 months of PI roll-out
• Top-line impact of Operational Awareness
• Data fit within a consistent Enterprise platform
• Use of templates / AF hierarchy structure = rapid
integration of new project sites
• Leverages existing sources of Metadata
• Extensive library of off-the-shelf interfaces available
from OSI
• Future data sources become an easy fit
36
Value now. Value over time.
© Copyright 2010, OSIsoft LLC All rights Reserved.
Click to edit Master title style
Information Driven
Collaboration
Kodak
“Energy Management
The Infrastructure Approach”
Dr. J. Patrick Kennedy,
CEO and President, OSIsoft
37
Empowering Business in Real Time.
© Copyright 2010, OSIsoft LLC All rights Reserved.
Click to edit Master title style
Information Driven Collaboration
Kodak Park
38
Value now. Value over time.
© Copyright 2010, OSIsoft LLC All rights Reserved.
Click to edit Master title style
Goals
• Reduce utility costs at Kodak Park through
improved demand side management
• Consolidation of the utilities data
• Create Awareness via the Web
• Grow a Culture of Energy Efficiency
39
Value now. Value over time.
© Copyright 2010, OSIsoft LLC All rights Reserved.
Click to edit Master title style
Employee Portal
40
Value now. Value over time.
© Copyright 2010, OSIsoft LLC All rights Reserved.
Click to edit Master title style
Mini Projects
•
•
41
Demand Side
•
Better correlation of MFG energy usage to production volumes
•
Identified opportunities in manufacturing to implement an energy conservation mode
between product runs
•
Extended carbon recovery cycles
•
More effective utilization of labs with fume hoods
•
More effective “Time of Day” scheduling for lighting and HVAC
•
Temperature / HVAC fan set points
•
System is considered an essential tool during our energy savings workshops (Kaizens)
•
Heightened awareness of many end users
Generation Side
•
Plant loading optimization
•
Boiler fan optimization
•
Exhaust head improvements
•
Better management of self generation vs. purchased power
•
Improved deaerator utilization
Value now. Value over time.
© Copyright 2010, OSIsoft LLC All rights Reserved.
Click to edit Master title style
Harvest Time - UPDATE
• The Energy Information System (EIS) has been an
essential tool to help us reach our goal of:
“One Powerhouse for Kodak Park”
(10:41:53 March 28, 2007)
• Collectively the “annual” savings rate in 2007 was
$27 Million
42
•
Today the “annual” savings has grown to more than
$30 Million
•
The cumulative savings is now in excess of $100
Million
Value now. Value over time.
© Copyright 2010, OSIsoft LLC All rights Reserved.
Click to edit Master title style
Lessons Learned
• Continuous Improvement Process
• No BIG BANG – 1000 little bangs
• Combined Capital and Intelligence Operation
• Infrastructure Approach – Remove Infrastructure
from Projects
• Lowers the Cost of Curiosity
43
Value now. Value over time.
© Copyright 2010, OSIsoft LLC All rights Reserved.
Click to edit Master title style
Energy Conservation Program – Continues
• Corporate Environmental Goals
• The last Goals were to Reduce Energy & GHG
Emissions 20% by 2008, from a 2002 Baseline.
We achieved roughly a 40% reduction in both.
• The new Goals are to Reduce Energy & GHG
Emissions 50% by 2012, from the 2002 Baseline.
44
Value now. Value over time.
© Copyright 2010, OSIsoft LLC All rights Reserved.
Click to edit Master title style
Solution – Current status – April 2010
45
•
Over 100,000 PI Points currently established
•
23 ProcessBook / DataLink Users
•
150 Concurrent Web Users
•
250 + iView Pages
•
30 Interfaces installed
Value now. Value over time.
© Copyright 2010, OSIsoft LLC All rights Reserved.
Click to edit Master title style
Eastman Business Park
Water Reduction Initiative
• 2009 Kodak Water Reduction was 16.5%
• 1,087,000,000 Gallons (or 1,087,000 K Gallons) saved
in 2009
• 1st Quarter of 2010 – an additional savings of 450
Million gallons from the 2008 Baseline
• Roughly 1.5 Billion Gallons saved in the last 15 Months
• $0.00 In Capital Spent
• These Water Savings are calculated for only the last 15
months and are totally independent of the site’s
energy reductions
46
Value now. Value over time.
© Copyright 2010, OSIsoft LLC All rights Reserved.
Click to edit Master title style
Conclusions


47
Think beyond automation.
Distinctive companies are collaborating with the following
outcomes;

Definition – agreed manufacturing objectives clearly
articulated, enabling contributions from all levels and areas.

Accountability – gaps and best practices identified,
initiatives prioritized, progress measured and verified.

Leveraged – surface and spread problems for efficient
resolution by limited experience resources.

Sustainable - fundamental change in the way you work.

Risk Averse - tools known, infrastructure in place.

Expected – matches skill set of emerging work force.

Peace of Mind – organization aligned, problems understood.
Empowering Business in Real Time.
© Copyright 2010, OSIsoft LLC All rights Reserved.
Click to edit Master title style
Thank you
Curt Hertler
curt@osisoft.com
© Copyright 2010 OSIsoft, LLC
777 Davis St., Suite 250 San Leandro, CA 94577