Manufacturing Productivity March 10 2010

1. Manufacturing Productivity March 10 2010 Practical Industrial Application of Process Diagnostics Alan Mason CEng FInstMC CChem MRSC CSci AJM Consulting Services Limited

2. “If you are responsible for the management or improvement of a process then you need to understand variability.” Dr W. Edwards Deming

3. Understanding and Reducing Variability • Probably the most cost-effective productivity improvement possible in any organisation • More consistent quality • Reduced waste and rework • Reduced processing costs • Reduced environmental impact • Improved delivery performance • Improved asset utilisation

4. Statistical Process Control (SPC)... • Standard tool for maintaining product quality • Focus on monitoring each variable in isolation LENGTH DIAMETER ...is unsuitable for most situations

5. SPC is not often appropriate in process management • No information is derived on interactions between variables • Understanding these is vital in complex processes

6. Multivariate Process Diagnostics • addresses interactions between variables • Understanding process complexity enables action to reduce variability • Early detection and diagnosis of faults prevents: • Reduced efficiency and consistency • Equipment damage, Plant shutdown, Hazardous situations • Prediction of outcomes allows for: • Variable input parameters

7. Most organisations are data rich... ...but information poor

8. Data is not an asset... Increase Productivity Increase Asset Value ...knowledge is!

9. Background to MS2 Diagnostics FIBRES WORLDWIDE 2002 Awareness of technology 2005 Prototype design 2007 Development Partners & EU Funding 2008 V5.0 released EuroPACT08 2009 V5.1 released APACT09 Now there are over 45 MS2 Users including… National Nuclear Laboratory >

10. Proven Benefits BREADTH OF INDUSTRIES – BREADTH OF BENEFITS

11. Example - Hip Replacement Planning • Responsibility for a ward processing hip replacement surgery • “Standard” bed residence is 8 nights • Some patients need longer • Expensive • Leads to cancelled operations Can we understand why this is, and can we predict it?

12. Data rich... WHY? WHY? ...Information poor

13. Let’s see if it is related to height... ...apparently not

14. Let’s see if it is related to weight... ...apparently not

15. But advanced analysis identifies height and weight as key contributors... ...what is going on?

16. Let’s plot height against weight... 8 nights or less More than 8 nights

17. Cause identified... BMI 8 nights or less More than 8 nights FATTER NORMAL SIZE THINNER ...abnormal height/weight ratio

18. Example - Hip Replacement Planning • Without advanced process diagnostics • We cannot predict a blocked bed • We must cancel operations at short notice • With advanced process diagnostics • We can predict a blocked bed • We can avoid cancelling operations at short notice

19. Example – complex reactor • It takes 48 hours to get the impurity result • Up to 48 hours of potentially high impurity • How can this be detected quickly? Bad samples (red) have high values of impurity Impurity % No single variable is in alarm Good samples (blue) have low values of impurity

20. Example – complex reactor If the scores plot (75 variables) moves as shown here, bad quality will result but no single point is in alarm

21. Example – complex reactor • Without advanced process diagnostics • We know if we had quality problems 48 hours ago • With advanced process diagnostics • We know if we have quality problems NOW Imagine you are a plant manager. Your chairman is visiting your plant with some institutional investors. One of them asks “are you making good quality product?”. There are two possible answers; “Don’t know. We were two days ago” “Yes” WHICH OF THESE ANSWERS IS CAREER-ENHANCING?

22. Industry applicability

23. CASE STUDY Sellafield is one of the most complex nuclear sites. The site is home to the Thorp and Magnox reprocessing plants, the Sellafield MOX plant and a wide range of waste management and effluent treatment facilities. The nuclear industry has invested substantial amounts of money in new plants to treat and package waste from reprocessing operations. Sellafield Ltd has utilised process data analysis using MS2 software in the 3 vitrification lines that convert concentrate liquid waste arising from reprocessing operations into glass for safe interim storage prior to long term disposal. ‘We approached AJM Consulting initially to evaluate the advantages of using multivariate process analysis. Following a successful trial using the MS2 software we were able to demonstrate the business benefit through the knowledge gained. So far the software has provided enough information to support a justification to make changes within our process operations for acceptance of batch composition. It has also made it easier to interrogate non-numerical databases and gain a better understanding in equipment performance and reliability. Further work is ongoing to develop the use of multivariate techniques to support continuous improvement activities within the business.’ Dr Carl Steele, Sellafield Ltd This document contains images and other content supplied by Sellafield Ltd.

24. FIBRES WORLDWIDE CASE STUDY Fibres Worldwide is a manufacturer of speciality carbon fibres. These have a wide variety of end uses including aerospace, electronics, medical, sports equipment and wind turbine blades. There is a need to understand the process in order to meet the stringent quality requirements of aerospace, medical and other end users and also for developing new, more demanding markets. “We were aware of the potential benefits of data mining to a process as complex as ours but we were concerned about its suitability for a continuous process. AJM was able to manipulate data from a large number of databases to produce a visualization. Subsequent multivariate analysis using MS2 has yielded valuable information about Key Process Parameters. We are looking forward to continuing to work with AJM to further develop the package by including customer data." Neil Barker, Fibres Worldwide Ltd

25. CASE STUDY Holliday Pigments is the world’s largest ultramarine blue pigment producer. The company is committed to continuously improving performance with increasing product diversity and quality demands. The manufacturing process is highly complex, often in areas where variability cannot be measured directly, for instance in kilns, or where the interaction of numerous variables is complex. ' The project has yielded some very promising results, confirming a number of firmly held views on the process whilst also challenging a few of our perceptions. Principal component analysis is of particular interest and has given us valuable insights into options to explore in control strategies and preventative maintenance. We look forward to applying MS2 to a wider set of data in the expectation there will be a few more hidden gems yet to be revealed' Glyn Jagger, Holliday Pigments Ltd

26. CASE STUDY "We had two reactors with differing characteristics which we did not fully understand. We had plenty of data from several systems but could not integrate it. MS2 integrated the data from our commercial, process control and plant historian systems and provided an effective visualisation of the problem and its cause, enabling us to implement changes which have resulted in increased consistency and quality.” “We are now implementing MS2 across the plant.” Stuart Askham Synthomer Ltd Synthomer is a world-class supplier of polymers to many industries. Quality is paramount. Achieving this means understanding the variability inherent in the manufacturing process. Synthomer selected MS2 to help identify causes of variability between multiple reaction vessels. This enabled Synthomer to implement changes which have resulted in improved manufacturing and quality performance.

27. CASE STUDY "We recognised substantial opportunities for performance improvement to be achieved by identifying the causes of subtle variability in this complex production process. We knew that we required a tool that could handle multivariate problems. We have now invested in the MS2 system and are using its powerful multivariate visualisation functions to further identify the opportunities to reduce variability, enabling us to optimise the profitability of the manufacturing operation." Martin Milburn, px Biodiesel Greenergy’s 200K tonne biodiesel plants (managed by px Biodiesel) are located at Immingham, which has sea, rail and road access as well as links to refineries. The plants use a variety of feedstocks including rapeseed, soy, palm and used cooking oils. Optimum management of this highly complex and innovative process requires a deep understanding of the production variables.

28. CASE STUDY Northumberland-based Aesica Pharmaceuticals supplies customers on every continent, from start-ups to global giants, a position achieved through advanced technology and manufacturing excellence. Committed to a process of continual striving for improvement, Aesica has invested in the MS2 Process Analysis System to assist in achieving ever-deeper understanding of process complexity. “The ability of the MS2 process analysis system to co-display a multitude of variables simultaneously then quickly identify interactions has already proved to be very useful. Whilst confirming some previously held beliefs there have been some genuine surprises in some of the causes behind process variability. It is this ability to handle and analyse diverse data sets in a user-friendly format which I believe will yield significant benefit to our many processes” John Budge, Aesica Pharmaceuticals Ltd

29. CASE STUDY Ciba’s Bradford site is one of the largest and most productive plants in the UK, with an output of over 250,000 tonnes of which 84% is exported. To assist in improving understanding of the complexities involved in its innovative processes, Ciba invested in the MS2 Process Diagnostics system and, with a team comprising in-house technologists augmented by specialists from AJM Consulting, has developed models which highlight causes of variability. "The ease of use of the MS2 system has been much appreciated by our highly qualified technical staff, who have been able to identify significant events that have been caused by subtle interactions further up stream. This has enhanced our understanding of our processes, enabling us to focus our improvement efforts on the critical areas in our plants. We see this as a key tool to achieve the next level of performance in our journey to operational excellence.” John Barratt, Head for Process Innovation and Development Centre

30. CASE STUDY CPI’s National Industrial Biotechnology Facility possesses state of the art process development facilities for industrial biotechnologists. The MS2 Process Diagnostics system is integrated with the DeltaV Process Control system provided by Emerson. MS2 enables the technologists at CPI to gain a far deeper understanding of highly innovative processes, helping to move towards full commercial realisation.   ‘MS2 is an excellent addition to the tools and technologies employed in the National Industrial Biotechnology Facility. It allows CPI to deliver better and faster services to our clients.’   Steve Donegan, Process Technology Manager “This capability means the data produced and subsequently interrogated will deliver for the future, creating integrated developments for new manufacturing processes for new products by design. CPI will produce more efficient and robust processes at a lower cost” Dr Chris Dowle, Director, Advanced Processes

31. CASE STUDY Johnson Matthey is focused on catalysis, precious metals, fine chemicals and process technology. It retains world leadership by adapting constantly to changing customer needs. With operations in over 30 countries, its products are sold around the world. It is a world leading manufacturer of catalysts for emissions control. The company has a worldwide reputation for excellence in catalysis and precious metals technology. Having assessed MS2’s applicability to its complex and highly innovative processes, the Company has now invested in eight MS2 systems, all of which include the advanced real time multivariate technologies developed by AJM Consulting’s EU-funded Project Hawk. "Our complex processes and continuous advancement in technology lead to a need for comprehensive understanding of our wide-ranging processes. To facilitate this we investigated the MS2 Process Diagnostics System. An initial trial on a single plant section proved its applicability to our business. We have now invested in more powerful versions of the system and are implementing it in various areas of our business where its ability to visualise the interactions between many variables assists us to improve our understanding of our innovative processes, upon which much of our business depends.” Mike Child, Johnson Matthey Some name Some position, Holliday Pigments Ltd

32. Summary • Data is not an asset; knowledge is • Traditional, single variable statistical techniques are inadequate to understand most problems • A cost-effective process diagnostics solution designed for ease of use and flexibility was needed and has been achieved • Users in many industries are experiencing real productivity improvements • Process diagnostics is probably the most cost-effective productivity improvement opportunity in any organisation

33. Thank You.Questions? The Process Diagnostics System