1 / 33

PI at

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

huey
Download Presentation

PI at

An Image/Link below is provided (as is) to download presentation Download Policy: Content on the Website is provided to you AS IS for your information and personal use and may not be sold / licensed / shared on other websites without getting consent from its author. Content is provided to you AS IS for your information and personal use only. Download presentation by click this link. While downloading, if for some reason you are not able to download a presentation, the publisher may have deleted the file from their server. During download, if you can't get a presentation, the file might be deleted by the publisher.

E N D

Presentation Transcript

  1. PI at More than just dessert!

  2. About Eastman… Headquarters: Kingsport, TN Manufactures and Markets Plastics, Chemicals & Fibers About 15,000 employees 30 countries 2000 sales: $5.3 billion.

  3. 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

  4. Presenters Johnette McDanielPrincipal Systems AnalystLongview, TexasLeader - PS-RLINK Worldwide Bill WightSystems AssociateKingsport, TennesseeProject ArchitectProcess Excellence Team

  5. 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

  6. What’s a “ ”? MESA Manufacturing Enterprise Systems Alignment Architecture

  7. 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

  8. 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

  9. 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

  10. Physical Architecture - II DELL NT Server SQLServer RS/6000 AIX Oracle TCP/IP PS-RLINK SM-IDI

  11. Archive Field Device Interfaces ProcessBook DataLink AlarmView Manual Logger (incl. HHT) BatchView SQC add-in PI Products

  12. Process Changes Datasheets SampleMonitor SPC Alarm Client Required Data Monitor LIMS Interface Statistical Analysis Facility Team “Products” MESA

  13. Manufacturing Business Processes Receive Raw Materials Prepare to Produce Monitor Manufacturing Qualify Product Post Production / Usage Management Information

  14. Collect Prepare Post Compare Respond Alert Monitor Manufacturing

  15. 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

  16. Collect & Compare Data About the Health of the Process To Expected Results Archive, Trends, HHT, Analyticals SampleMonitor DataSheets SQC Add-in • Monitor Manufacturing

  17. Alert & Respond Operator to Deviations Capture Response For Later Analysis PIAlarmView MESA Alarm Client Select and RecordCauses & Actions • Monitor Manufacturing

  18. Manufacturing Business Processes Receive Raw Materials Prepare to Produce Monitor Manufacturing Qualify Product Post Production / Usage Management Information

  19. Configure Manage Post Monitor Post Production / Usage Customizations Unsolicited Messages Standard Features

  20. 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

  21. 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.

  22. Unsolicited Messages PI to SAP • Material Transfers • Batch Creation (PI_BT_CR) • Batch Characteristics (PI_BT_CL)

  23. 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

  24. Configure Automated Configuration Tools Bulk Configuration Digital Tags PS-RLINK Tags Testing

  25. ManageAutomated User Tools Control Recipe Stop/Start Confirmation Materials Maintenance

  26. Monitor Interface Monitoring & Intervention I/T Support Alarms User Alarms Debugging Tools

  27. PS-RLINK Statistics • 6 Manufacturing Divisions • 89 Resources (Reporting Locations) • >800 Materials • >12,000 MT Reported Daily • Minimal Problems

  28. Of course, there’s still… Dessert!

  29. Manufacturing Business Processes Receive Raw Materials Prepare to Produce Monitor Manufacturing Qualify Product Post Production / Usage Management Information

  30. 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

  31. Required Data Monitor…ensuring that critical data is archived Configure Monitor

  32. Cognos PowerPlay & Impromptu

  33. 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

More Related