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PI at. More than just dessert!. About Eastman…. Headquarters: Kingsport, TN Manufactures and Markets Plastics, Chemicals & Fibers About 15,000 employees 30 countries 2000 sales: $5.3 billion. Manufacturing Sites. Kallo, Belguim. Middelburg, Netherlands. Rotterdam, Netherlands
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PI at More than just dessert!
About Eastman… Headquarters: Kingsport, TN Manufactures and Markets Plastics, Chemicals & Fibers About 15,000 employees 30 countries 2000 sales: $5.3 billion.
Manufacturing Sites Kallo, Belguim Middelburg, Netherlands Rotterdam, Netherlands PTA & PET Molndal, Sweeden Workington Rexdale, Ontario, Canada Hartlepool Stonehouse, UK Carpentersville, IL Bury, UK South Holland, IL Pleasant Prairie, WI Hamburg, Germany specialty polymers Kingsport, TN hundreds of chemicals, fibers & plastics Waterford, Ireland Toronto, Canada PET Nanjing, China easTotac hydrocarbon tackifying resin (to be completed late 2000) Dusseldorf, Ger. specialty polymers Wales fine chemicals Tanggu, China Newark, NJ Portland, OR Philadelphia, PA Lynwood, CA Sokolov, Czech Republic textile chemicals Jefferson, PA Franklin, VA Batesville, AR specialty organic chemicals Nan Ping, China LaVergne, TN Cola’ Di Lazise, Italy Columbia, SC PET Hong Kong pharmaceutical intermediates Ennis, TX Roebuck, SC textile chemicals Sant’ Albano, Italy Jurong Town, Singapore Spain PET & CHDM Kuantan, Malaysia Eastar & Spectar Savannah, GA Singapore OXO chemicals Longview, TX over 40 chemicals & plastics Forest Park,, GA Columbus, GA Moundsville, AL Uruapan, Mexico Veracruz, Mexico PET Argentina PET
Presenters Johnette McDanielPrincipal Systems AnalystLongview, TexasLeader - PS-RLINK Worldwide Bill WightSystems AssociateKingsport, TennesseeProject ArchitectProcess Excellence Team
MESA Manufacturing Enterprise Systems Alignment History of PI at Eastman ‘90 - 40,000 tags - Utilities Control System ‘93 - Manufacturing Process Improvement- Utilities Expands Functionality ‘94 - Manufacturing Links to AI Tools (EPC)- Interface PI to Internal MES’s ‘95 - Full Information System (Different Archive) ‘97 - Began MESA Project (1.6M tags) ‘99 - Two Latin American Plants in Operation ‘01 - North American Startup
What’s a “ ”? MESA Manufacturing Enterprise Systems Alignment Architecture
CONSOLIDATED Bus. Intel. Analysis Mgmt. Summary Process/ Product Knowledge Decision Support EIW Area-specific customization PIMS Common User View R/3 LIMS COMPREHENSIVE COORDINATED Planning Ship Inventory Management Process Conditions Execution Production Records Lab Inst. Schedule Process Control Initiate Production Runs ProductArchitecture
Mgmt. Reporting Oper. Reporting Measures “Roll-up” MIS Data Feeds Sample Mgmt. Instrument Interfacing SPC Data Feed Calibration Standards Methods D.A. LIMS R/3 Process Data Collection Data Archiving Trend Displays Excel Interface Perf. Equations SPC Std. Displays Lab Data Access Calc. Production Calc. Usage PI PI MS Inventory Tracking Planning/Scheduling Batch Records Quality Release Process Recipes Process Instructions Cert. Of Analysis Shipping Functional Architecture
Data Analysis Record Analyses Process Data Apply Statistics Physical Architecture - I • Information SAP • Materials (R/3) R/3 Track Materials • PIMS • Purchased LIMS • Scales, PCS
Physical Architecture - II DELL NT Server SQLServer RS/6000 AIX Oracle TCP/IP PS-RLINK SM-IDI
Archive Field Device Interfaces ProcessBook DataLink AlarmView Manual Logger (incl. HHT) BatchView SQC add-in PI Products
Process Changes Datasheets SampleMonitor SPC Alarm Client Required Data Monitor LIMS Interface Statistical Analysis Facility Team “Products” MESA
Manufacturing Business Processes Receive Raw Materials Prepare to Produce Monitor Manufacturing Qualify Product Post Production / Usage Management Information
Collect Prepare Post Compare Respond Alert Monitor Manufacturing
Prepare Establish Process Conditions Process Changes Utility • To LIMS: • Product ID • Batch No. • Process State • To PI: • State Tags • SPC Limits • Other Tag Settings • Monitor Manufacturing
Collect & Compare Data About the Health of the Process To Expected Results Archive, Trends, HHT, Analyticals SampleMonitor DataSheets SQC Add-in • Monitor Manufacturing
Alert & Respond Operator to Deviations Capture Response For Later Analysis PIAlarmView MESA Alarm Client Select and RecordCauses & Actions • Monitor Manufacturing
Manufacturing Business Processes Receive Raw Materials Prepare to Produce Monitor Manufacturing Qualify Product Post Production / Usage Management Information
Configure Manage Post Monitor Post Production / Usage Customizations Unsolicited Messages Standard Features
Standard Features PI-PCS Interface • Start/Stop Control Recipes & Phases • Processbook • Automated via Excel • Post actual Production, Consumption & Activity quantities • Backflush Consumption Quantities (Unrestricted and Restricted) • Varying Levels of Automation
Post Production Default from PI tags. Default current time. (User can change) User selects Calculated from flow rate PI tag. User can change. Calculated from LBS User selects Default Default from PI tags.
Unsolicited Messages PI to SAP • Material Transfers • Batch Creation (PI_BT_CR) • Batch Characteristics (PI_BT_CL)
Customizations • SAP to PI-Tag Value Updates • Quality Test Results from SAP to PI • System Management and Alarming • Eastman Wrappers • Recipe Management • Post Production/Usage/Activities • Automated Tools
Configure Automated Configuration Tools Bulk Configuration Digital Tags PS-RLINK Tags Testing
ManageAutomated User Tools Control Recipe Stop/Start Confirmation Materials Maintenance
Monitor Interface Monitoring & Intervention I/T Support Alarms User Alarms Debugging Tools
PS-RLINK Statistics • 6 Manufacturing Divisions • 89 Resources (Reporting Locations) • >800 Materials • >12,000 MT Reported Daily • Minimal Problems
Of course, there’s still… Dessert!
Manufacturing Business Processes Receive Raw Materials Prepare to Produce Monitor Manufacturing Qualify Product Post Production / Usage Management Information
Tools for Power Users PI DataLink: Ad Hoc Query / End-User Dev. Stat. Analysis Facility: Quality System Maintenance Chart Delivery ProcessBook: Process Data vs. Analytical Data
Required Data Monitor…ensuring that critical data is archived Configure Monitor
Manufacturing Sites Kallo, Belguim Middelburg, Netherlands Rotterdam, Netherlands PTA & PET Molndal, Sweeden Workington Rexdale, Ontario, Canada Hartlepool Stonehouse, UK Carpentersville, IL Bury, UK South Holland, IL Pleasant Prairie, WI Hamburg, Germany specialty polymers Kingsport, TN hundreds of chemicals, fibers & plastics Waterford, Ireland Toronto, Canada PET Nanjing, China easTotac hydrocarbon tackifying resin (to be completed late 2000) Dusseldorf, Ger. specialty polymers Wales fine chemicals Questions? Tanggu, China Newark, NJ Portland, OR Philadelphia, PA Lynwood, CA Sokolov, Czech Republic textile chemicals Jefferson, PA Franklin, VA Batesville, AR specialty organic chemicals Nan Ping, China LaVergne, TN Cola’ Di Lazise, Italy Columbia, SC PET Hong Kong pharmaceutical intermediates Ennis, TX Roebuck, SC textile chemicals Sant’ Albano, Italy Jurong Town, Singapore Spain PET & CHDM Kuantan, Malaysia Eastar & Spectar Savannah, GA Singapore OXO chemicals Longview, TX over 40 chemicals & plastics Forest Park,, GA Columbus, GA Moundsville, AL Uruapan, Mexico Veracruz, Mexico PET Argentina PET