Globales Anlagenmonitoring und analytische Datenauswertung in der Produktion zur Erhöhung der Produktivität und zur Verbesserung der Planung

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1 Hannover Messe International - Vortrag 25. April 2012 Globales Anlagenmonitoring und analytische Datenauswertung in der Produktion zur Erhöhung der Produktivität und zur Verbesserung der Planung Ralf Thiemann, Lothar Zügel

2 Agenda 25. April Ansätze, Methoden und Werkzeuge 2 Voraussetzung Integration 3 Analyse, Optimierung und Verarbeitung grosser Datenmengen 4 Projekt Beispiel Globales Monitoring und Daten Analyse von Windparks 5 Referenz Projekt Effizientes Energie und Ressourcen (Wasser) Management 6 Diskussion und Fragen? 2

3 Ansätze, Methoden und Werkzeuge zur Produktivitätssteigerung und Transparenz Advanced Condition Monitoring: Predictive Asset Management : Entscheidungsunterstützung durch Vernetzung mit Daten aus Produktionsssystemen zur statistischen Analyse Statistische Modellierung historischer und aktueller Daten zur vorausschauenden Planung und Fehlererkennung. New Data Sensors and Metering Event Processing + Real Time Data Integration New Insights 3 Ereignis Verarbeitung und Visualisierung aus unterschiedlichen heterogenen Quellen Predictive + Historical Analytics Data Data Statistische Analyse und Korrelation von Ereignissen und historischen Quellen zur Entscheidungsunterstützung Visualization, Rules & Visualisierung der Information in rollenbasierten Portalen mit hinterlegten Geschäftsregeln Data Data Modeling Modeling Collaboration Process Innovation U.a Sensor Echtzeit Daten und Zählerstände New, Visualization Optimized Business & Visualization & and Lifecycle Processes Decisions Decisions Nutzen in Anwendungen und Unternehmensweiten Prozessen

4 AC Voraussetzung ist die Intelligente Vernetzung der Unternehmens- und Planungssysteme mit der Produktion Decision Support System,Rollen basierte Cockpits, ERP, Business Equipment Analytics Analytics Operational Effectiveness Asset Effectiveness Production Optimization Performance Management Ressource Efficiency Weitere Anwendungen Water, Energy, Materials... Integrated Data Platform (Integrated Information Core / IIC) Workflow, Value-added Semantic Reference Models, Rules engine (Jrules), Event/action, ETL, Application Integration,... Smart Equipment (high value assets) Data Collection/On boarding Systems, 4

5 Statistische vorausschauende Analyse Predictive Analytics System Analytics for through the windscreen view. Predictive insights improve management and refine business rules Real Time Insights ACM Pro-Active Response Planning Insight Asset Management System 5 Powerful rear view mirror data source for Monitoring, Reporting & Managing based on past and very recent events Maintenance planning tool integrated within PAM and ACM For alerting maintenance to forecast alarm / risk conditions For identifying near term preventative interventions Actionable Insights BI System For reporting from asset mgt system and for distribution of predictive analytics insights which have opeartional significance

6 Optimierung hilft Entscheidungen zu verbessern What-If Analysis Collaboration 6 ILOG, All rights reserved

7 Verarbeitung grosser (un)strukturierter Daten Mengen aus heterogenen und verteilten Systemen Analytics on Big Data at rest Real-time analytics Volumes of raw data (structured and unstructured) in file systems (often highly distributed) Data Warehouse BigInsights Operationa l Data Store 7 Applications Business Analytics InfoSphere Information Server IBM Confidential InfoSphere Streams Real-time streaming data (structured and unstructured) Predictive Analytics Event detection and capture of real-time data Traditional data sources (ERP, CRM, databases, etc.)

8 Agenda 25. April Ansätze, Methoden und Werkzeuge 2 Voraussetzung Integration 3 Analyse, Optimierung und Verarbeitung grosser Datenmengen 4 Projekt Beispiel Globales Monitoring und Daten Analyse von Windparks 5 Referenz Projekt Effizientes Energie und Ressourcen (Wasser) Management 6 Diskussion und Fragen? 8

9 Renewables Transformation Path Maturity e o tiv rati c e g eff inte n i s se me a re ste Inc r Sy we o P n Optimize - e.g. Predictive Analytics Manage - e.g. Condition-based Maintenance Monitor - e.g. KPI s, dashboards Time

10 Plattform Scope 10 Remote Monitoring and Control: Business Performance Management & Analytics: Global, Regional, Site, Turbine, Sub-Station level real-time monitoring & Control Automated event based error handling Shared Service Platform across geographies Curtailment Tracking Operational and Business KPI reporting in real-time Optimized Power Prediction and input to trading New project planning, scheduling and tracking Predictive Maintenance & optimised Shutdown Planning Energy Accounting & Production Cost Calculations Asset and Power Generation Optimisation: Technical Excellence and Procurement: Asset Optimization & Component level inventory management on global level Proactive spare parts management Asset Insurance management Speedy emergency response Energy Scheduling and Load Forecasting Uncover trends, patterns from turbine errors Historical Analysis of Turbine performance Modelling and Simulation of optimal site location based on historic wind directions Comparison of actual power curves w.r.t. to OEM power curves 10

11 Projekt Zielsetzungen Management Planungs Team Global Monitoring Regional Site leve Regional Betrieb Management Report & Analytics Turbine Site Schedule Unified Information Model Control Weather Forecast Market Pricing Workforce Mgmt. N 11

12 Reference case study IBM Burlington Advanced Water & Energy Management IBM 200 mm Wafer Fabricator Challenge Reduce water consumption (and associated need for energy, chemicals, maintenance and labor) to reduce operating cost and minimize environmental impacts Approach 12 Implemented data collection and storage infrastructure: sensors, IT network and servers Statistical process control techniques used to continually analyze vast amounts of operational data and present information in efficient, concise interface IBM s Green Sigma methodology breaks down water usage by process: Dashboards convey key process indicators Identifies process improvements that reduce water consumption and provide other benefits, such as reduced electrical power consumption, Results IBM has achieved over $3.6M in annual savings, reduced water usage by 27% while increasing manufacturing capability over 30%

13 Burlington Advanced Water & Energy Management ph, RO Feed Strt Date: 1/6/2009 End Date: 1/7/2009 Method: Modified Control Limits Data: 96 subgroups of 15 samples, 1 min. rate Status: Operations RO Feed ph 6 X-Bar S Chart, 1 Day DI Central, SPC SPC X-Bar Chart: ph, RO Feed ph 6.00 Xbar UCL LCL USL LSL 4.20 Common Carbon Outlet Flow : :15 04:15 06:15 08:15 12:15 14:15 16:15 18:15 20:15 22:15 Com Subgroup Time 1000 Maximo 10: Std Dev 0.5 Booster Pmp Dis. Pres. 200 Visualization and Optimization Emergency Response Asset Mgmt. Modelling and Analytics Event Mgmt. UCL Std Dev SPC Sigma Chart: ph, RO Feed :15 LCL 02:15 04:15 06:15 08:15 10:15 12:15 14:15 16:15 18:15 20:15 22:15 Subgroup Time Integrated Information Framework Existing SCADA 13 Control Devices Advanced Sensors Disparate Data Sources 13

14 Diskussion und Fragen??? Kontakt Ralf Thiemann, Lothar Zügel,