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Empowering Business in Real Time. © Copyright 2009, OSIsoft Inc. All rights Reserved. Value Now with Enterprise Services Regional Seminar Series Beth Murray.

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Presentation on theme: "Empowering Business in Real Time. © Copyright 2009, OSIsoft Inc. All rights Reserved. Value Now with Enterprise Services Regional Seminar Series Beth Murray."— Presentation transcript:

1 Empowering Business in Real Time. © Copyright 2009, OSIsoft Inc. All rights Reserved. Value Now with Enterprise Services Regional Seminar Series Beth Murray Enterprise PI Administrator RockTenn 11-August-2009

2 2 Empowering Business in Real Time. © Copyright 2009, OSIsoft Inc. All rights Reserved. Overview RockTenn – Who & Why Justification Implementation Adoption & Utilization Results Whats Next for PI at RockTenn

3 3 Empowering Business in Real Time. © Copyright 2009, OSIsoft Inc. All rights Reserved. Who is RockTenn? One of North Americas leading manufacturers of paperboard, containerboard, consumer and corrugated packaging and merchandising displays Annual net sales of approximately $3 billion Founded in 1936 and operates manufacturing facilities throughout the United States, Canada, Mexico, Argentina and Chile 11 Recycle Paperboard Mills, 1 Recycle Container-board Mill, 1 Bleached Board Mill 90+ Converting Plants Headquartered in Norcross, Georgia

4 4 Empowering Business in Real Time. © Copyright 2009, OSIsoft Inc. All rights Reserved. Challenges and Obstacles Our Challenges – Controlling Costs (Energy, Fiber, Labor, and Maintenance) – Producing Consistent, High Quality Paperboard – Operating at Maximum Reliability and Efficiency – Using Data to Drive Process Improvement – Six Sigma The Obstacles – Mis- & Missing Information – No History, No Visibility, No Real-Time Feedback – You dont know you need the data, until you need the data The discouraging part of process improvement is trying to get a complete set of data together in one place. When it is too hard to get, you have to leave it out of the analysis. We are missing opportunities to act on information and save money General Manager, Cincinnati Mill

5 5 Empowering Business in Real Time. © Copyright 2009, OSIsoft Inc. All rights Reserved. How Do We Remove Obstacles? Implement a highly flexible and configurable enterprise-wide information system to: – Collect and archive detailed, actionable data from all existing processes and systems – Put data on any desktop, laptop or monitor across the company – Provide tools for reporting and analysis – Empower users to make informed decisions Home Grown? Third Party?.

6 6 Empowering Business in Real Time. © Copyright 2009, OSIsoft Inc. All rights Reserved. The Proposed Solution... PI System Enterprise Services

7 7 Empowering Business in Real Time. © Copyright 2009, OSIsoft Inc. All rights Reserved. Enterprise Project Manager Architecture Assistance Software Upgrades Available services include: Training Extranet OSIsoft Installation/ Configuration Under an executed Enterprise Program Agreement, customers have access to a cumulative knowledge base built upon 25 years as an industry leader. Enterprise Program Agreement Services Access to Center of Excellence Asset Monitoring Enterprise Program Agreement

8 8 Empowering Business in Real Time. © Copyright 2009, OSIsoft Inc. All rights Reserved. How Do We Justify the Investment? Energy! Actively pursue energy cost reduction through the capture and review of data to: – Monitor and adjust process to run at higher efficiency – Alert to energy excursions and correct them quickly – Create an energy balance to find heat recovery opportunities – Monitor and analyze energy market pricing to adjust plant consumption patterns – Optimize energy per ton with other process inputs – Determine unit ops energy cost and benchmark all mills

9 9 Empowering Business in Real Time. © Copyright 2009, OSIsoft Inc. All rights Reserved. Why Energy? One of the top three costs Fuel – Fiber – Folks $170 million per year 19 million MMBtu equivalents per year 90% used by the 12 paperboard mills We cant control the energy markets We Can Control Our Energy Usage

10 10 Empowering Business in Real Time. © Copyright 2009, OSIsoft Inc. All rights Reserved. Implementation Strategy Business Unit driven, not IT Deploy rapidly, 10 locations in 12 months 11 th installed March09, 12 th installed July 09 Scope: Connect to whats available Initially one of three types of process data Single internal resource = Reliance on Enterprise Project Mgr (EPM) & Field Service Engineers Install it and they will come. Standardize or Customize? Plant-led development and adoption

11 11 Empowering Business in Real Time. © Copyright 2009, OSIsoft Inc. All rights Reserved. Seven Hills RockTenn PI Installations Missisquoi Chattanooga Battle Creek Stroudsburg St. Paul Dallas Aurora Eaton Cincinnati Demopolis Norcross Solvay (future EA)

12 12 Empowering Business in Real Time. © Copyright 2009, OSIsoft Inc. All rights Reserved. Installation Summary 10 Mill Locations + Corp. Office in first 12 Months – OSIsoft Field Service Engineer On Site 11 weeks 1 installed Q1 2009, 1 installed Q – OSIsoft Field Service Engineer Remote Average 750 connections per day >100,000 Tags 10 Different Interfaces 84 Interface Instances OSI Network Op Ctr (NOC) Quarterly Reviews Center of Excellence (CoE)

13 13 Empowering Business in Real Time. © Copyright 2009, OSIsoft Inc. All rights Reserved. Installation Details We did not know what we did not know! Initial Schedule was too aggressive On site survey with plant engineer and IT The hardest part of the installation often determining how to connect to the data. Upgrades and OPC servers had to be purchased. Scheduled installation week with OSI. SMS deployment package for PI client software. Establish remote access to interface nodes. Allow OSIs NOC to log into our PI servers.

14 14 Empowering Business in Real Time. © Copyright 2009, OSIsoft Inc. All rights Reserved. Getting Started Training and Awareness – What is PI? – Initial training during installation week – Purchased 6 laptops and wireless hub – Individual user specific training with CBTs & EA Training Vouchers – On-site group training with EPM, CoE & Learning Labs – Power Users: tag admin and advanced topics

15 15 Empowering Business in Real Time. © Copyright 2009, OSIsoft Inc. All rights Reserved. What is PI?

16 16 Empowering Business in Real Time. © Copyright 2009, OSIsoft Inc. All rights Reserved. Pie? Mmmm. Blackberry.

17 17 Empowering Business in Real Time. © Copyright 2009, OSIsoft Inc. All rights Reserved. An Irrational Number?

18 18 Empowering Business in Real Time. © Copyright 2009, OSIsoft Inc. All rights Reserved. Something Greek?

19 19 Empowering Business in Real Time. © Copyright 2009, OSIsoft Inc. All rights Reserved. A Private Investigator? Sort of...

20 20 Empowering Business in Real Time. © Copyright 2009, OSIsoft Inc. All rights Reserved. Like Magnum P.I.?

21 21 Empowering Business in Real Time. © Copyright 2009, OSIsoft Inc. All rights Reserved. No! PI = Plant Information

22 22 Empowering Business in Real Time. © Copyright 2009, OSIsoft Inc. All rights Reserved. Bringing Data Together JDE Financials Process Controls and Metering Process Controls and Metering Front Office Systems Plant Floor Systems AS/400 Mill System Business / MES AS/400 Mill System Business / MES Order Entry Customer Service Scheduling Production Roll Labeling and Tracking Quality Lab Shipping / Inventory / Backlog Invoicing / Sales Accounts Payable Accounts Receivable P&L Data Time & Attendance Internet / Intranet Energy prices Invoice Search Backlog Sales Power House DCS PLCs Recorders Meters Gas Oil Steam Electricity OSI PI Data Historian Scanners & Gauging Systems

23 23 Empowering Business in Real Time. © Copyright 2009, OSIsoft Inc. All rights Reserved. Commonly Used Features PI DataLink PI ProcessBook PI ProfileView - 3D display of paperboard sheet RtAlerts Transpara Visual KPIs

24 24 Empowering Business in Real Time. © Copyright 2009, OSIsoft Inc. All rights Reserved. Acceptance & Utilization Mixed mill management support At least one early adopter at each mill Application development driven by local needs Divisional priorities identified with CoE Value Realization Process (VRP) Requires both Subject Matter Experts and PI Experts Utilization?

25 25 Empowering Business in Real Time. © Copyright 2009, OSIsoft Inc. All rights Reserved. Utilization Tool – PI-Processbook Add-in

26 26 Empowering Business in Real Time. © Copyright 2009, OSIsoft Inc. All rights Reserved. Results Energy Reductions > $1,000,000 Fewer Customer Complaints Improved Paper Machine Efficiency Standardized Visualization & Benchmarking Six Sigma Process Capability Analysis

27 27 Empowering Business in Real Time. © Copyright 2009, OSIsoft Inc. All rights Reserved. The PI Effect: Energy Reduction Initial PI installation, Oct Began using PI trends to monitor pulper steam usage Made procedure changes to limit pulper steam usage Reduced steam usage 41% Reduced boiler gas consumption 23% Half of gas reduction attributable to pulper steam > $1,000,000

28 28 Empowering Business in Real Time. © Copyright 2009, OSIsoft Inc. All rights Reserved. Visibility of Steam Usage…

29 29 Empowering Business in Real Time. © Copyright 2009, OSIsoft Inc. All rights Reserved....Lowers Boiler Gas Consumption 55% 42%

30 30 Empowering Business in Real Time. © Copyright 2009, OSIsoft Inc. All rights Reserved....The Fastest PI Savings

31 31 Empowering Business in Real Time. © Copyright 2009, OSIsoft Inc. All rights Reserved. Customer Complaint Reduction Plant received a warp complaint Manually researching quality and process data was time consuming and inconclusive Reviewing the PI ProfileView images revealed back edge caliper and moisture streaks Corrective action – Use PI process trends and RtAlerts to notify supervisors of variances – Created a spreadsheet that captures all quality and process data for each reel in real-time Results – reduced warp complaints and claims

32 32 Empowering Business in Real Time. © Copyright 2009, OSIsoft Inc. All rights Reserved. CaliperBasis WtMoisture Plant Profile

33 33 Empowering Business in Real Time. © Copyright 2009, OSIsoft Inc. All rights Reserved. Paper Machine Efficiency PM experienced more breaks and lost time due to draw variations Developed a dashboard with R-Y-G indicators for tight and loose draws PM efficiency has improved by one percentage point 1% efficiency improvement equals 2.5 TPD

34 34 Empowering Business in Real Time. © Copyright 2009, OSIsoft Inc. All rights Reserved. Draw Indicators

35 35 Empowering Business in Real Time. © Copyright 2009, OSIsoft Inc. All rights Reserved. 1% Improvement in Efficiency

36 36 Empowering Business in Real Time. © Copyright 2009, OSIsoft Inc. All rights Reserved. Standardize Displays & Benchmark

37 37 Empowering Business in Real Time. © Copyright 2009, OSIsoft Inc. All rights Reserved. Buy / Gen Decision Tool

38 38 Empowering Business in Real Time. © Copyright 2009, OSIsoft Inc. All rights Reserved. Standard Report

39 39 Empowering Business in Real Time. © Copyright 2009, OSIsoft Inc. All rights Reserved. Visual KPI Add On Display

40 40 Empowering Business in Real Time. © Copyright 2009, OSIsoft Inc. All rights Reserved. Power Users Monthly conference calls Semi-annual face-to-face meetings SharePoint portal for collaboration & information Share and leverage applications across all mills Discuss standards and naming conventions Learn new tools and software Create RtAlerts CoE involved in many of the above items

41 41 Empowering Business in Real Time. © Copyright 2009, OSIsoft Inc. All rights Reserved. How was IT Involved? Project justification Hardware and networking strategy, spec, and install Archiving strategy with OSI Rolling out OSI applications to users Application development Future involvement: System Architecture design with CoE Application Development Using PI tools to monitor IT environment

42 42 Empowering Business in Real Time. © Copyright 2009, OSIsoft Inc. All rights Reserved. Lessons Learned Planning vs. Speed – Its a tradeoff Engage IT in project planning

43 43 Empowering Business in Real Time. © Copyright 2009, OSIsoft Inc. All rights Reserved. Corporate Dashboard Center of Excellence and Value Realization Software Upgrades Next Steps: Training ExtranetLearning Labs Value Later with Enterprise Services Bi-Weekly Calls Asset Monitoring Ongoing Enterprise Services

44 44 Empowering Business in Real Time. © Copyright 2009, OSIsoft Inc. All rights Reserved. What is the Future of PI? Build an asset-based DB RtWebParts rCAAM Integrate more data/systems Extend to other divisions Continue to move to the board room - Corporate Dashboard

45 45 Empowering Business in Real Time. © Copyright 2009, OSIsoft Inc. All rights Reserved. CoE Engagement VRP (Value Realization Process) Lynchburg learning labs Kaizen (Power users) planning and implementation (training) Corp Dashboard – identified in VRP - restructuring – Architectural recommendation received – Project advisory during implementation Division reports Bi-weekly calls ( CoE Status updates and SI updates) Quarterly reviews General Support/Best Practices – PI to PI, MiniTab, PI-Manual Logger, etc

46 Thank you © Copyright 2009 OSIsoft, Inc. 777 Davis St., Suite 250 San Leandro, CA 94577


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