Reaching across boundaries, collaboration, Web Parts, and Notifications

1. Reaching across boundaries, collaboration, Web Parts, and Notifications Jim Cummins Manager: Process Information

2. SMI: Sharing Information World Wide “Specialty Minerals has a very dispersed work force with small facilities located around the world. Consolidating and surfacing production information is essential for daily management. Web Parts is a tool that integrates well with our web based communications. “ Customer Business Challenge Solution Customer Results / Benefits • Collect accurate process information from small facilities located globally. • Provide a single source for viewing many locations and processes to employees in non centralized locations. • Communicate requirements to suppliers for automated deliveries. • Implemented a single PI server with interfaces to manufacturing facilities world wide. • Implemented MS SharePoint with PI web parts to expose process information. • Implemented notifications tied to inventory to Email suppliers. • Dashboards and process analysis are driving continuous improvement ; lowering product costs improving performance. • Integration of information from multiple data sources. • Timely, reliable, communication for material suppliers.

3. Specialty Minerals Synthetic Calcium Carbonate Facilities: 53 located globally Employees: 3 to 15 per location Symbiotic relationship with paper mill MTI Proprietary Technology PCC Plant PCC Slurry Lime Source Gas Paper Mill H20 Paper Machine Chemical Sources Power Waste Local Labor

4. Facility Design Facilities are highly automated using Siemens PCS7 DCS systems. Plants are or can be operated by a single individual or in many cases unmanned for periods of time. Plants will run continuously 24X7 as needed to meet mill demand. Product is delivered to host mill by pipe line. Off site customers are supported with truck deliveries.

5. Our History with OSIsoft PI server was installed in Easton PA. data center in 2007. Data interfaces were installed at 8 facilities replacing local data Historians. Additional facilities were added in 2007 and 2008 including locations in Europe, Africa, South America, and Asia. PI ACE was added to populate batch tables in SQL Server. MS SharePoint Server was deployed with PI Web parts to expose process data on the secure company network. PI to PI interface has been used to link directly with the customer. PI Notifications has been used to communicate inventory levels to raw material suppliers.

6. Interface and data collections Each of the facilities use a PI OPC interface installed on the Siemens PCS7 process control system operator interface computer. Process data is continuously streamed to the central server. Data is buffered at the plant in the event of a connectivity loss. PI Batch and PI ACE are used to create batch records in SQL Server.

7. Challenge Business processes needed to be stream lined. Data quality, Timeliness, Labor, results distribution.

8. Challenge: Time to collect and Quality of data Collecting information from each plant required many forms and manual data collection

9. ChallengeData consolidation and Analysis

10. Challengedata storage, access, and reporting

11. Challenge Business processes needed to be stream lined. Data quality, Timeliness, Labor, results distribution.

12. Solution Business processes needed to be stream lined. Data quality, Timeliness, Labor, and Reporting .

13. The Solution: Data Collection Install PI Server in Easton PA with interface to all facilities. Collect process data for each plant using PI OPC Interface Implement PIBaGen (PI Batch Generator) Utilize PI Process Book and Data Link One Source for process information One version of the truth

14. The Solution: Consolidation Collect process data for each plant on one server. Implement ACE to create Batch Records in SQL Server. Plant information Roll up capabilities One Source for process information. One version of the truth.

15. The Solution: Reporting Expose summary information using MS SharePoint PI Web Parts for quick summary of process information PI Notifications for supplier communication One Source for process information. One version of the truth.

16. Solution Business processes needed to be stream lined. Data quality, Timeliness, Labor, and Reporting .

17. Content Management Collaboration Intranet / Extranet MOSS Business Intelligence Electronic Forms Search Connection to each facility MTI Firewall PI Historian and web server PI WebParts End user tools Plant Firewall HMI Local Programming OPC Interface Production network Office network SIMATIC S7 Typical Plant Configuration

18. “Extensible Server design” Initial Setup Company Wide Implementation Controlling cost Expansion capability over time without losing past investment Growth

19. Significant steps to implementation Initial deployment of PI Install and manage PI server. Install and manage interface on each control system. Use PI client tools including data link and process book to involve end users. Show immediate benefits in data acquisition and analysis. Listen for suggestions to improve analysis.

20. Significant steps to implementation Add more value over time with each new application. Install and manage PI Batch. Install and manage PI ACE. Install SQL Server. Configure your batch triggers and create batch records from continuous data. Involve end users. Show immediate benefits in data acquisition and analysis.

21. Significant steps to implementation Add value with each new application Install and manage MS SharePoint . Install PI Web Parts and Baseline. Create and publish batch summaries using tree view, table views, Time, and batch view. Create pages to show plant KPIs, production, and other related information. Involve end users.

22. Significant steps to Benefits Listen to end users and get them involved. Develop actionable web pages from web parts to support internal company operations, management, and reporting requirements. Improve your relationship with customers by implementing a PI to PI interface to their PI system. Communicate to suppliers using PI Notifications.

23. Benefits One source of the truth + Improved accuracy + Faster recognition of opportunities + Informed decisions = Lower costs

24. Benefits Reduced time to collect and collate data Removes one roadblock to unmanned operation Accurate and verifiable data Removes one roadblock to unmanned operation One source for process data Every one works off the same data source Reduction in time spent validating information One version of the truth

25. Benefits Process metrics including OEE calculations Data to measure KPIs Real time access to information from anywhere Export from web site to Excel for unique analysis using third party modeling software.

26. Content Management Collaboration Intranet / Extranet MOSS Business Intelligence Electronic Forms Search Supporting the Continuous Improvement Process Identify Opportunity PI Web Parts Feedback Collect Data Solution With WebParts Analysis

27. Current Challenges Migration from SharePoint 2003 to SharePoint 2007 Building content at the rate it is requested.

28. SMI: Sharing Information World Wide “Specialty Minerals has a very dispersed work force with small facilities located around the world. Consolidating and surfacing production information is essential for daily management. Web Parts is a tool that integrates well with our web based communications. “ Customer Business Challenge Solution Customer Results / Benefits • Collect accurate process information from small facilities located globally. • Provide a single source for viewing many locations and processes to employees in non centralized locations. • Communicate requirements to suppliers for automated deliveries. • Implemented a single PI server with interfaces to manufacturing facilities world wide. • Implemented MS SharePoint with PI web parts to expose process information. • Implemented notifications tied to inventory to Email suppliers. • Dashboards and process analysis are driving continuous improvement ; lowering product costs improving performance. • Integration of information from multiple data sources. • Timely, reliable, communication for material suppliers.

29. Jim Cummins Manager: Process Information Specialty Minerals Inc. Jim.Cummins@mineralstech.com Thank you