plant to enterprise in a multi-site environment

© 2008 Akzo Nobel Base Chemicals BV | Atos Origin Nederland BV

Plant to EnterprisePlant to Enterprisein a multi-site environmentin a multi-site environment

Plant to EnterprisePlant to Enterprisein a multi-site environmentin a multi-site environment

Peter Luttje Peter Luttje Bert WissinkBert WissinkPeter Luttje Peter Luttje Bert WissinkBert Wissink

3© 2008 Akzo Nobel Base Chemicals BV | Atos Origin Nederland BV

AgendaAgenda

IntroductionWhat is our PI mission?What have we encountered?How did we solve it?What did we learn?What are the benefits?


1. Introduction1. Introduction

Companies involved

– Akzo Nobel Base Chemicals BV• Sub Business Units: Chlorine, MCA, Energy, Salt and

Ecosystems

– Atos Origin Nederland BV• Enterprise Solutions unit MES


1. Introduction: AkzoNobel1. Introduction: AkzoNobel

Serving customers throughout the world with coatings and chemicals

€ 14.4 bln sales60,000 employees in more than 80 countriesCommitted to delivering Tomorrow’s Answers TodayHeadquartered in AmsterdamGlobal Fortune 500 companyListed on the Euronext Amsterdam stock exchangeTop position on the Dow Jones Sustainability

Indexes and FTSE4Good


1. Introduction: Akzo Nobel Base Chemicals BV1. Introduction: Akzo Nobel Base Chemicals BV

Total revenues € 900 mln, excl. JV’s 1,650 Employees Business areas: Salt, Energy, Chlor-Alkali,

Ecosystems, MCA Leading position in Europe for chemical

transformation salt, chlorine and caustic lye for industrial applications

Worldwide number one position in monochloroacetic acid (MCA)

Products play a key role in the production of glass, textile, detergents, building, automotive, pharmaceuticals, plastics and disinfectants


1. Introduction: Akzo Nobel Base Chemicals BV1. Introduction: Akzo Nobel Base Chemicals BV

LeMoyneTaixing Ohmi

Skoghall

Mariager

DelfzijlDeventer

RotterdamArnhem Bitterfeld

HengeloIbbenbüren

Active in 7 countries

Manufacturing (16 plants/ 9 locations)

2 R&D locations

3 Joint ventures


1. Operational excellence in an integrated business model1. Operational excellence in an integrated business model

Salt and Energy

Inte

rnal

Cus

tom

ers

External Customers

SaltBrine

purification

Dissolvingunderground

salt

FuelCo-

Generation

Electricity

Steam

Electrolysis

H2

Cl2

NaOHHypoCI

MCA

HCI

FeCIx

Chlor Alkali Ecosystems and MCA

Salt


AgendaAgenda



2. Our PI Mission2. Our PI Mission

Run a project program to have PI working in all plants by the end of 2010

Plant to Enterprise Challenge– 4 sub Business Units– 2 Continents– 5 Countries– 8 Sites– 19 Plants– Multiple languages and cultures– 1 Production chain– 1 SAP system– 1 HQ in Amersfoort (NL)


2. Our PI Mission2. Our PI Mission

Linking Organizations to IT standards


2. Mission: Where we come from2. Mission: Where we come from

ChlorineBIT

ChlorineIRN

ChlorineDZL

ABB Emerson Honeywell

Plant

DCS

ERP

ChlorineHGL

ChlorineRDM

SaltDZL

ValmetHoney-

well

SaltHGL

SaltMGR

EnergyDZL

EnergyHGL

EnergyRDM

ABB Honey-well

Honey-well

FoxboroFoxboro Foxboro

MES

SAP BC SAP Salt SAP Energy

Progres

PI

Progres

Excel PHD PHD SQL

ChlorineSHL

MCASHL

Emerson DeltaV

Excel

PI2 PHD Fox-com

Navision

Fox-comFox-com

FisherRS/3

Germany Netherlands Sweden Netherlands Denmark Netherlands

MCAHGL

Foxboro

PHD

SAP FC

Excel

MCATXN

Emerson

Excel

China

Excel


2. Mission: Initial Objective2. Mission: Initial Objective

Harmonize on– One MES platform– KPI definitions– Production Accounting– Interfacing with SAP– One Way-of-Working

By deploying– Standard software where possible

And striving for– Low Total Cost of Ownership


2. Mission: Projected Result in 20102. Mission: Projected Result in 2010

ChlorineBIT

ChlorineIRN

ChlorineDZL

ABB Emerson Honeywell

Plant

DCS

ERP

MCADZL

ChlorineRDM

SaltDZL

Metso Honeywell

SaltHGL

SaltMGR

EnergyDZL

EnergyHGL

EnergyRDM

ABB Honey-well

Honey-well

Honey-well

Emerson

MES

ChlorineSHL

MCASHL

Emerson

Germany Netherlands Sweden Netherlands Denmark Netherlands

SAP

MCATXN

Emerson

China

OSIsoft PI

Production Accounting Solution “X”


AgendaAgenda



3. What have we encountered?3. What have we encountered?

Project Organization– Corporate program– Local projects

Harmonization– Multiple plants on 1 PI system– Multiple languages and cultures– Visualization

Integration– Network load (LAN, WAN)– Process Control Layer (security)– SAP Interfacing

Production Accounting– Transaction based vs. real-time– Find a suitable solution


AgendaAgenda



4. How did we solve it?4. How did we solve it?

Project Organization– Fixed core project team– One Akzo Nobel focal point– One Atos Origin project manager– Local focal point per project

Harmonization by balancing– Standardization

• Tag naming convention• PI security on tags and data• Corporate PI Web enabled portals

– Differentiation• Reference manuals in local languages• Local PI Portals



Integration– Network load: Prioritize PI network traffic– Security on Process Control Layer: Firewalls– SAP: OSIsoft RLINK

Production Accounting– Standard OSIsoft modules did not fit our purpose– Tailor Made solution– One Way-of-Working


End of Part 1End of Part 1

LAN Arnhem Velperweg

CentralPI Server

Wide Area Network

LAN Delfzijl

PI ServerPI PortalServer

RLINKServer

PI Interface NodeSalt

DeltaV App NodeMEB & MCA

LAN Rotterdam

Foxcomm NodeEVB

PI Interface NodeEVB

PI Interface NodeMEB Rdm

PI Interface NodeMEB Rdm

LAN Ibbenbüren

DeltaV App StationIbbenbüren

LAN Bitterfeld

ABB IMS StationBitterfeld

LAN Skoghall

PI Interface Node PI Interface NodeLAN Hengelo

PI Interface NodeSalinco

PHD NodeDelesto


1. Introduction – Part 21. Introduction – Part 2

Companies involved

– Akzo Nobel Base Chemicals BV• Sub Business Units: Chlorine, MCA, Energy, Salt and

Ecosystems

– Atos Origin Nederland BV• Enterprise Solutions unit MES


1. Introduction: Atos Origin1. Introduction: Atos Origin

Leading IT services companyProviding consulting, systems

integration and outsourcing solutions

Delivering business outcomes globally

– Annual revenues of € 5.8 billion– Over 50,000 employees– In 40 countries worldwide


North AmericaNorth America

700700

South AmericaSouth America

1.9001.900

UKUK

6.2006.200BeneluxBenelux

10.20010.200

FranceFrance

15.80015.800

AfricaAfrica

200200

Central EuropeCentral Europe

4.0004.000Asia PacificAsia Pacific

4.0004.000SpainSpain

6.0006.000

1. Introduction: Atos Origin - Global Presence1. Introduction: Atos Origin - Global Presence

In total more than 50.000 employees worldwide


AgendaAgenda




Production AccountingPI PortalsSAP integration


4. Solutions: Production Accounting4. Solutions: Production Accounting

Definition:

“ To account for intake, produced products, available stocks and delivered goods ”

Characteristics:

• Interactive transactional way-of-working• Based on real-time PI data (pipeline customers)• Needs verified data (€’s involved)• Results are input for invoicing through SAP• Typical users are plant controllers


4. Solutions: PACE Architecture4. Solutions: PACE Architecture

PI Server

PI Plant data

Production Accounting

PerformanceEquations

Totalizers

Production Accounting Data

PI ProductionAccounting data

Other software

Process Control Layer

Process ControlSystem

PI Interface Node

PI interface

Local Buffer

Production Accounting Calculation Engine

ProductionAccountingFormulas

Manage Formulas

Collect

Calculate

FormulaParser

External Systems

External data

Manual Input

ManualCorrections

FileloaderStart Reports

Production AccountingReporting

Excel +PI DataLink

Production AccountingResults

Reports

Standard OSIsoft PI


4. Solutions: PACE initial setup4. Solutions: PACE initial setup

LAN

Local File Server

`

End-user PC

LAN

PI Server

WAN

PACEdatabase


4. Solutions: PACE future setup4. Solutions: PACE future setup

Application Server

PI ServerMS SQL Server

Web Server

`

End-user PC

Database Layer

Business Layer

Presentation Layer


4. Solutions: PACE screens4. Solutions: PACE screens


4. Solutions: PACE Benefits4. Solutions: PACE Benefits

Ease of Use– Management of calculations by end-users– Validations and corrections– Testing of formulas

Starting-points achieved– Automatic calculation sequence – Interactive recalculation– Support monthly calculations– Calendar based

Other Benefits– Support for periodic closures – Support for freeze of data– One Way-of-Working


4. Solutions: PI Portals4. Solutions: PI Portals


4. Solutions: RtWebParts Maturity Examples4. Solutions: RtWebParts Maturity Examples


RLINK in practiceRLINK in practice

Prerequisites– Make clear functional specs– SAP configuration needs to be ready

Lessons-learned– Implementation “a tough nut to crack”– Tricks and work-arounds needed– Use it as it is intended, don’t cross borders– Configuration GUI is too “buggy”– User Manual is too technical (not “accessible”)

…once running it’s very stable


End of part 2End of part 2


AgendaAgenda



5. What did we learn?5. What did we learn?

Maturity of RtWebPartsPrepare well for RLINKReconsider Production Accounting setupImportance of availabilityImportance of validated data


AgendaAgenda



5. Benefits5. Benefits

Improved Harmonization– One Way-of-Working– Uniformity on Production Accounting– Plant data available for every seat at every site

Improved Insights– Corporate Management dashboards– View on overall performance – View on consumptions, stocks and deliveries

Improved Business Processes– Plant benchmarking possibilities– Improved support for logistics department– Improved Production Planning

New Opportunities


5. Benefits: Future Plans5. Benefits: Future Plans

Technical Improvements– Upgrade RtWebParts– Improve PI availability with High Availability PI– Realize PI Dev/QA environment– Improve data integrity

Support Excellence programs– Study PI - SAP Plant Maintenance opportunities– Study Condition Based Maintenance feasibility


Conclusions Conclusions

Project success– Management commitment – Fixed core project team– Local involvement– Availability of plant employees– Flexibility and anticipation– Standardization and differentiation well balanced

PI and PACE success– Improved our business– Good fit– Opens doors to new opportunities


Final RemarkFinal Remark

Plant to Enterprise

=

Empowering Business in Real Time


[email protected]

+31 (0)6 5322 0468

[email protected]

+31 (0)6 5158 2000

plant to enterprise in a multi-site environment

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