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From yield optimization to manufacturing cost control

From yield optimization to manufacturing cost control. OXOCHIMIE Lavera - France François GERMAIN Plant manager. Oxochimie. Bienvenue en Provence. Lavera en Provence. Lavera site. ELF ATOCHEM. 33.600 PEOPLE. 43 Bn$ TURNOVER. OXOCHIMIE - 1999. BPA CHEMICALS. 17.000 PEOPLE.

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From yield optimization to manufacturing cost control

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  1. From yield optimization to manufacturing cost control OXOCHIMIE Lavera - France François GERMAIN Plant manager

  2. Oxochimie

  3. Bienvenue en Provence

  4. Lavera en Provence

  5. Lavera site

  6. ELF ATOCHEM 33.600 PEOPLE 43 Bn$ TURNOVER OXOCHIMIE - 1999 BPA CHEMICALS 17.000 PEOPLE 14 Bn$ TURNOVER 50 % OXOCHIMIE 100 PEOPLE 100 M$ TURNOVER 50 %

  7. What are we doing? • We are making basic chemicals • Production de 300 000 Tonnes/year of OXO-alcohols • Applications for plasticisers, paints, inks, solvents… • 5th world producer of Oxo-alcohols

  8. Summary 1. Before PI 2. A fast track project 3. Rapids benefits of PI 4. Reports 5. Data reconciliation + demo 6. Link to manufacturing costs

  9. When? PRINTOUTS RE-KEYING OF DATA LABORATORYREPORTS TELEPHONE CALLS Time consuming to consolidate reports HUMAN ERROR Before PI

  10. The PI project • Initiated by Elf group • Limitation with DCS historical(ABB MOD 300) • Motivated team for installing the PI system • Fast project • Immediate results

  11. Project planning • Dec 96: Project definition • Jan 97: Project kickoff • Feb 97: Hardware purchase • March 97: PI start up • Avril 97: User training • June 97: Laboratory transfer on PI • Feb 98: Automatic daily reports • March 98: Manufacturing costs

  12. PI implementation • DCS: ABB MOD 300 • Alpha server 1000A 5 / 333 - VMS 7.1 • PI2 license 5000 tags (3800 used) • existing PC network (W95)

  13. What they say about PI (1) Console operator« It is a great advantage of PI above DCS historical, Process Book gives facilities to configure appropriate scales, time ranges, tags… » Shift supervisor« When you are back on the plant after a shift break, we do identifie previous modifications . With 2 or 3 clicks we get the right information… »

  14. What they say about PI (2) Day foreman« The system is user friendly » Lab supervisor« By mixing lab data and process, we do understand the quality variations » Logistic engineer« With PI and associated tools, we really get the right data. Time consuming is divided by 3 »

  15. What they say about PI (3) PI administrator« The PI system gave me hard days at start up,but It is a pleasure to see people happy with it » Site general Manager «PI is the good tool, we will install it on the other plants »

  16. Rapid benefits • After training phase, Process book was largely used for trouble shooting mainly • Every incident is investigated with PI • Increased reliability • Daily optimization • Obtain returns

  17. Plant reliability %

  18. Daily reporting • Manufacturing report show yield variations and performance • Laboratory reports include process data • PI Data link + PI Perf equation usage • Replacement of our rekeyed report by automatic PI reports

  19. Morning manufacturing report

  20. Morning laboratory report

  21. Other reports • Monthly manufacturing report: Totaliser tags: integration of daily rates • Identification and reconstruction of plant model (unit by unit): mass balance • Maintenance report: usage rate of equipments

  22. Corporate application tools used • X / Y add-in in Procbook for correlation study • Comparison of laboratory analysis versus on line analyzer • Temperature profile analysis for tubular reactors • SQC reports from laboratory (Excel 97)

  23. Data reconciliation • Complexity of numerous units and links • What is Datrec? • Demo

  24. Complexity of units products links

  25. What is Datrec • Reconciliate data • Detect faulty measurement device • Compute daily/monthly material balance for the whole plant from raw materials to finished products • Developed by Elf research center (Solaize) • Distributed by Honeywell and Technip

  26. General characteristics • Treat any redundancy equation:- Linear (mass balance) - Non linear (energy balance, constituent balance) • Estimate the missing measurements • Power of maths in user friendly interface • PI Interface (through PI API):- instantaneous - average - integration

  27. Results with Datrec • Gets accuratecoherent and reliable data to generate yield and mass balance • Improves data quality, feed back of faulty values • Feeds sound data for manufacturing costs calculation

  28. PI / Datrec / Cost system PI Daily balance Plant DATREC Data PC VCS Production report COSTS Monthly balance

  29. DATREC DEMO

  30. Manufacturing cost project Objectives: • Calculate the variable costs of productions based on market prices. • Generate quantity repartition by product for each shareholder

  31. VCS OXOPRINCIPLES • PI: collect technical data + mass balance + analysis of deviations • DATREC: reconciliate data • PC: chemicals consumption and prices • VCS:Variable Cost system. feed stock balance (production / stocks / sales). consumption by product - cost calculation of each product - product cost for each shareholder - variance reports

  32. Questions ?

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