Production visibility: KPI’s in Real-time BASF – The Chemical Company

1. Production visibility: KPI’s in Real-timeBASF – The Chemical Company Sharon Brown Wonderware S.A.

2. Introduction BASF - The Chemical Company “We were able to reduce scrap, downtime and smoothed change-overs by the increase in total visibility of our production process”

3. Introduction Project Solution Agenda Benefits Considerations Summary

4. BASF – Chemical Company • International Company • Diversified foot print around the world • Chemicals are it main business • In South Africa, it includes plastics, polyurethanes, agricultural, leather, chemical and automotive sectors. • BASF Port Elizabeth • Catalytic converter industry • One of the highest users of precious metals for the automotive sector • Roughly 39% market share, which represents roughly 5.5 million parts in 2008.

5. Process Background • Slurry Manufacturing • Mixing • Customer / Part Specific • Mixing • Slurry are mixed • Q/A • Quality checks • Manage waste • Production • Coating lines • Various machines – client chosen technology MIXING AREA SLURRY AREA COATING LINES LABORATORY / QA PRODUCTION AREA

6. Introduction Project Solution Agenda Benefits Considerations Summary

7. Topology - Before new installation Network TCP/IP (LAN) InTouch 22 Stations Appr. 50 000 I/O 25 K Historian 10 A/F Clients Siemens (S7) on Ethernet SLURRY AREA InTouch SCADA MS SQL Server MIXING AREA LAB / QA InTouch SCADA LIMS – ORACLE DB PRODUCTION AREA InTouch SCADA

8. Key Requirements • No real-time visibility of the process. • Equipment Status • Process Status • Maintenance Status • Lack of communication between production and maintenance staff due to lack of information. • No access to key performance indicators • Production variables • Production Rate / Figures

9. Key Requirements • More central monitoring of production flow • The information was only available at SCADA level at the machine • Required access to production reports by management

10. Project Goals - Technical • Install a central repository of real-time data that links the current SCADA’s, production databases and LIMS data. • Capitalize on already available infrastructure of Wonderware SCADA and Historian • Make the operation more visually representative to all involved using a Web interface

11. Project Goals - Business • Due to the nature of the business, the raw material are of extreme high value • i.e. precious metals – platinum • Main goal is to keep scrap levels as low as possible and minimize rework and production cost. • How?

12. How to realize these Goals • Need to reduce downtime • Anticipate production problems • Departments to take joint responsibility for critical dependencies • Reduce change-over times • Improve overall coating rate

13. Why Wonderware • Existing Wonderwareinstall base. • InTouch SCADA network of appr. 50 000 I/O • Wonderware Historian 2K5 and Active Factory clients • BASF wanted to utilise their present investment • Scalability of the Wonderwaresolution

14. Why Wonderware • Information Server from Wonderware (WIS) provided a solution • Good working relationshiphas been built up with the supplier • Top quality trainingis provided

15. Project Solution • Solution aimed at making the information more centrallyaccessible • Control Room environment • Web Clients for managers • Displayingthe coating, slurry and operation information • Production Data • Downtime • Machine and process Status

16. Implementation - Prerequisites • First step Involveproduction and maintenance resources to determine the information needed • Made each person Responsiblefor the availability of the data by • Training • Do own modifications on the SCADA Taking ownership of the system

17. How it was implemented • Installed the Wonderware Information Server (WIS) • Gather data from various systems in the plant • Both Wonderware and other sources. • Control room set up with multiple large LCD displays • Both production and maintenance used. • Build web based reports for management • Project took 3 months

18. Data acquired – Multiple Sources ACTIVE FACTORY / WE CLIENTS InTouch Oracle DB SCADA Systems LIMS Historian / Information Server COATING LINES • SLURRY MANUFACTURING MS SQL Server 2005 MS SQL Server 2005 CONTROL ROOM

19. Topology Network TCP/IP (LAN) Active Factory Clients SLURRY AREA InTouch SCADA Plant PLC’s MS SQL Server MIXING AREA LAB / QA InTouch SCADA Wonderware Historian MS SQL Server Web Portal – Information Server LIMS – ORACLE DB Plant PLC’s CONTROL ROOM PRODUCTION AREA InTouch SCADA WIS Clients Plant PLC’s

20. Control Room • Wonderware Information Server (WIS) Clients Multi Views KPI’s Downtime Status Alarm Conditions Real-time Graphics InTouch Trends and Charts Historian Average rates of the coating. Drill-down Reports Table Weaver Collaborating Data from different sources

21. Introduction Project Solution Agenda Benefits Considerations Summary

22. Benefits / Goals Achieved

23. Introduction Project Solution Agenda Benefits Considerations Summary

24. Considerations • Infrastructure (PLC network and LAN) was in place which made it easier to gather the data • We started by doing training first • Involving maintenance, production and process engineering made the project run smoother

25. Introduction Project Solution Agenda Benefits Considerations Summary

26. In Conclusion Richard Mangold Service Platform Manager “ The Wonderware package is very broad, the more training and awareness, the more it can be utilized becomes a true asset to the company.” “Attend more sessions, breakfasts and road shows – the benefits are there!”

27. Questions Thank you for attending