Performance Management for the Cement Industry

IndustrialIT: Performance Management for the Cement Industry  InformIT Knowledge Manager

InformIT Knowledge Manager  All production 

Profitability

knowledge at your  fingertips. You need easy access

Best Practice

to timely, accurate, reliable information  in order to enhance enterprise-wide productivity.

SAP Experience

Knowledge

Real-Time Performance Monitoring

Statistical Production  Analysis Production Information Management

Knowledge Manager

Excel  Add in

SAP Integration

LIMS

Production  Accounting

Dispatch  Automation Solution

Microsoft Excel

 AutoLab Quality Robotics

Process Data Management Raw Data Process Control

Knowledge Manager:

• Maximizes the economic performance of your  assets • Enables you to reach environmental, production and quality  goals

«Produce quality products more effectively» Effective production management

Modular design

If you have the specific information you need at

The core of Knowledge Manager comprises all

the right time and the right place in the right for-

the functions and components needed for indus-

mat, your decisions will be more goal oriented, and

try specific process and quality data warehousing

 you will be able to optimize processes and incre-

and focused information presentation. Knowledge

ase productivity. With Knowledge Manager, part

Manager can be adapted and expanded to meet

of ABB's

InformIT

application suite, you have the

each company's specific requirements, and can

solution and advanced tools you need to facilitate

incorporate up to several hundred users in order to

the collection, organization and distribution of pro-

keep pace with growing demand.

duction and quality information throughout your plant organization.

• Supports the achievement of  quality management by integrating process, production and  quality information 

Saving you money  Knowledge Manager's flat learning curve saves you instruction and implementation time. Research into information systems technology, software programming or interfacing is unnecessary . For example,

the industry-specific applications are available as a set of ready built but configurable objects, enabling you to capitalize on the expertise of others

• Supports defined   work processes and ensures manpower efficiency   by delivering rele vant operation  information for  improved decision making 

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 who have already developed equivalent solutions. Quite simply, you enter the learning curve at a much higher level. The time needed to produce a  working solution is much shorter, involving less risk and less lead-time before on-site knowledge management begins. You decide how much of the solution development you wish to do in-house and how much assistance you would like ABB to provide.

Savings of up to US$500k in every  installation: • Real-time automated key performance indicators (KPIs) to support decisionmaking, enabling best-in-class manufacturing, saving up to US$300k per year  • Emission tracking and compliance certificates, saving up to 2 people weeks every  month  • 2 people weeks saved every month  through advanced material balancing  tools • US$200k saving through SAP integration  and consultancy  • Quality optimization, tracking and  management, saving up to 2 people years per year 

Production Information Management

« A powerful aid to help monitor plant performance» InformIT Knowledge Manager Production Informa-

duction situation: product stocks, capacities of pro-

tion Management drastically simplifies production

cess equipment, availability, etc. Better utilization

management, covering production related func-

of energy, equipment, inventories and capacities

tions like:

can be expected.

• production tracking and reporting • process operations monitoring and reporting

Process operation support helps process managers

• material storage management, and

identify the influences that process parameters

• energy and emission reporting.

have on product quality, production capacity, etc.

Fast and informed  decisions: • Increased production through   best-in-class  work practices, greater focus and deeper   understanding 

It combines production related data, process varia-

Identifying the influences that process parameters

bility, energy indexes, run-time quality parameters,

have on product quality, production capacity, ener-

etc. in comprehensive process operation reports.

gy consumption and emission levels is now easier

Connectivity to ERP systems (SAP, BAAN, People-

than ever. Powerful analysis tools are available at

Soft, etc.) is nowadays an essential tool to bring

the click of a mouse button. After all, successful

production data from floor level to enterprise

process information is key to your plant operation.

management level. Knowledge Manager serves

The Knowledge Manager production management

here as the information broker between the real-

functionality includes running plant overview and

time control and production environment and the

specific calculating and reporting capabilities for

transactional based ERP systems.

• Real-time manufacturing  performance and target monitoring for continuous improvement 

production, material storage and emissions. access to information without delays. Knowledge

 With Knowledge Manager, production and  process managers become empowered know-

Manager provides reliable reports on the plant pro-

ledge workers.

The key to production planning is the online

Performance Monitoring  – Process analysis  – Process visualization  – Operation reporting  – Charts & trending  – Production data analysis and reporting

 – Production management support  – Key Performance Indicators  – Energy reporting  – Material and stock reporting  – Environmental reporting

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Production Information Management

 Take the guess  work out of  maintenance: • Identify real  and costly   weakpoints in production  process • Forecast the next maintenance event  • Improve plant  equipment  availability and  efficiency 

«Minimize plant equipment down-time» Is downtime earning you money? Most definitely 

Pareto analysis is based on configurable causes

not. Reducing downtime and keeping up produc-

based on a plant definable fishbone diagram. Reli-

tion capacity is vital for any production plant. And

able statistical information on downtime causes

correct information is the key. The Knowledge

is the basis for corrective action. The information

Manager Downtime Management and Mainte-

is essential for justification of capital expenditure,

nance Support solution ensures you know for cer-

personnel training, etc.

tain what your most costly problems are, taking the guesswork out of maintenance by integrating

Direct integration of information into your ERP

facilities for easy identification of failing equip-

(Enterprise Resource Planning) system is an

ment. Pareto analysis is used to find out the real

obvious advantage. Transferring stop logs, running

and most costly weak points in the production

hours, downtime statistics, etc. to SAP's PM and PP

process and provides support for forecasting the

module, is a matter of plug and play. It eliminates

next maintenance event.

the work of the manual input through the SAP GUI.  Although automatic, it allows for validation, manu-

Identification of failing equipment is based on

al correction and approval by the maintenance and

event and alarm statistics. Results are issued dai-

production manager before transfer. Through inter-

ly/weekly in e.g. TOP TEN forms. Maintenance

faces like these, we protect your long-term invest-

events of specific process equipment are forecas-

ments by making use of industry standards.

ted by using equipment running hours, production totals, cumulative energy utilization, etc.

Downtime Management and Maintenance Support  – Maintenance forecasting support  – Root cause analysis  – Pareto analysis on production stops and failures  – Production stop reporting

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 – Low rate production reporting  – Key performance indicators  – Running hours administration  – Alarm and event recording and analysis

Cement Production Accounting

«Reconcile production results quickly»  Within the cement industry, production accounting

Knowledge Manager automatically takes care

activities are usually focused on the month-end

of the reconciliation of related data so that the

closing and on the day-to-day administration of 

database remains consistent. Any further reports

materials, consumption and efficiency. The regular

 will show figures that are consistent with pre-

challenge of making production results coherent

 vious reports. For systematic and re-occurring

and consistent is drastically simplified and sped

adjustments, variable factors can be applied on

up with Knowledge Manager's Cement Production

the source data. When the factors are adjusted

 Accountant.

systematically, a learning effect is achieved and

Production data  inevitably require  balancing and  reconcilation   before reporting.

the relative discrepancies will minimize over time. In the Knowledge Manager environment, all the

Historical analysis of the correction factor schemes

required data is automatically collected from the

provides valuable information to minimize accoun-

different subsystems on the plant such as process

ting efforts.

control systems, the dispatch system, sales administration and so on. The data is then rolled-up

Further improvement is achieved in the automated

and calculated into a one-page overview. Detected

day-to-day administration of materials. By using

discrepancies between figures are highlighted.

advanced stock tracking mechanisms, available

 You can then drill down into each of the results to

data is automatically calculated. The latest and best

consult the data hierarchy, the calculations and the

possible estimates of non-instrumented storage

input data that produced the particular result. Data

locations such as stockpiles and bulk silos are pro-

can be adjusted and the new results previewed.

 vided.

Cement Production Accountant  – Production accounting overviews  – Material balancing  – Data drill down/ result transparency   – Advanced stock tracking  – Dispatch connectivity 

 – ERP connectivity   – Manual/automatic data correction/ adjustment  – Historical correction schemes with learning capability   – Data reconciliation

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Excel Add-In

Information  available in Excel 

Having an impromtu meeting?  Use extensive Excel tools to provide: • Additional KPIs • Performance

«Ad hoc reporting quickly » Sourcing the right information from everywhere,

simply select the data required. With underlying

manually typing it in, transferring it to the right for-

direct web queries, the data is retrieved from one or

mat, etc. for a report that had to be ready 

more servers simultaneously. Thus the production

 yesterday? The Knowledge Manager Excel Add-In

information is available for further processing and

makes user specific ad hoc reporting much easi er.

formatting with standard Excel functions. Important-

 You can run queries directly from the Excel spreads-

ly, this bi-directional link can easily be used for bulk

heet without the need to write SQL queries. You

data correction in Knowledge Manager.

reviews • Budget plans • Cement quality  reviews and  forecasting  • Process models and studies

Excel Add In  – Retrieval of all available data to Excel  – Bi-directional for bulk data correction  – Multiple retrievals per spreadsheet  – Retrieve data from multiple servers

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 – Easy pick & choose  – Shortcut buttons for common selections  – No SQL language required  – Store selection for reuse

Knowledge Manager SAP Connector How is the business performing?

 Applications:

SAP MM/SD

Management

PP-PI

PM

Production, Orders, Deliveries, Goods Received

Operations Production Sales Maintenance Quality

Production, Material and Energy Consumption

Knowledge Manager Production Information Manager

How is the plant performing?

Production  Accounting

LIMS

• Production  costing  • Production  planing  • Material  management  • Plant  maintenance • Extensive KPIs

Process Data Management

Control System

Manual Entries

Laboratory

«Extend your knowledge by integration with your SAP System» The Knowledge Manager SAP Connector extends

The engineering and configuration of the SAP con-

the reach of Knowledge Manager into enterprise

nector is done through the Knowledge Manager

applications by supporting the direct interaction

 Application Developer Toolkit, i.e. the same tools

between the manufacturing processes with SAP

and methods used for report configuration are

ERP software.

used to configure the SAP Connectors. No specific

Using this connector, the manufacturing informati-

knowledge of the SAP internals, or SAP interface

on integrates with the SAP; and the business infor-

technologies, and most importantly no knowledge

mation from SAP integrates to the manufacturing

of software development is required to use or

environment in a smooth and accurate way.

configure the connectors. On SAP no specific cus-

 All the methods required for connecting to SAP and transferring the manufacturing information are fun-

tomization is required in most of the modules; the

damental to the Knowledge Manager SAP Connector.

re-entering of data with electronic data transfer.

SAP Interface provides: • Online integration of manufacturing in overall   business process • Packed solution   based on standard methods • Short implementation time

Knowledge Manager SAP Connector replaces the

• Easy to maintain, no SAP experts required 

SAP Interface  – Manufacturing information integrated in SAP  – Business information integrated in KM  – No specific knowledge of SAP programming required  – Engineering and configuration through KM toolkit

 – Online exchange of information between SAP and KM  – SAP PP-PI connector  – SAP PM connetor  – SAP MM/SD connector

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Laboratory Information Management System

 The Knowledge Manager LIMS is designed to manage process quality information according  to proven lab practices.

 The coordination  of process, production and laboratory tasks makes LIMS a reliable  backbone for the day-to-day running of a professional laboratory:

«Integrate laboratory management with enterprise-wide production» InformIT Knowledge Manager LIMS covers all

logging procedures, sample status reports, work

laboratory tasks for the entire process and issues

lists, standard and compliance reporting features,

compliance certificates. Naturally it's fully integra-

easy-to-use trending and graphing plus options for

ted with enterprise-wide process and production

Excel and statistical analysis applications.

monitoring, downtime support and maintenance management.

• Benefit from   unique, seemless and full  integration of  information 

LIMS provides advanced means of documenting quality information and makes it easily accessible in a transparent way. It provides operations with timely quality information on the process, thus increasing actionable knowledge. Knowledge

• Visualize and   better understand the relat-

Manager LIMS provides the foundation for direct process management and process quality control on a day-to-day basis. It is designed to enhance

ionship between 

process improvements and to provide a firm basis

process conditions and quality  results

for your further production. Included are functions such as automatic and manual data acquisition, data validation, data consolidation, long-term storage, calculations, sample

LIMS  – Automatic or manual sample registration  – Sample scheduling/worklist  – Manual entry forms  – Sample status list  – Sample survey sheet

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 – Analysis/ test reports  – Quality reports  – Color-coded outliers  – Compliance reports  – Graphical presentations and charts

Statistical Production Analysis

CUSUM, or CUmulative SUM, chart,  used for deviation  control, with the  V mask dynamically 

plotted.

«Correct product quality during production» Statistical Process Control (SPC) information enables operators to compensate for or to eliminate

Statistical process control charts contribute to process and quality improvement:

Statistical Production Analysis provides powerful  tools to:

causes before out-of-specification product is produced. In Inform IT Knowledge Manager Statistical

• They provide a picture of the condition of the

Production Analysis, the trend functions X Chart,

process and the improvement of the quality 

EWMA chart and CUSUM chart have been selected

over time;

to match manufacturing process specific requirements. The X-Y graphs provide the facility to plot two variables against each other to see the possib-

• They provide information for correction of  causes and for improvement of the process;

le correlation between them with automatic compensation of time delay. Histograms allow for rea-

• They indicate the process capability – what it is

dable statistics of run-time quality measurements.

actually capable of doing during attributable cause correction and process improvement acti-

In SPC, the quality is emphasized as a process

• Effectively  monitor quality  related process  variables

 vities.

characteristic. If the process is controlled and

• Verify if the  variables are randomly scattered around  the mean and  normally distri buted 

improved, product quality will be maximized auto-

• Detect changes in variability  and determine changes in the process average

matically. Therefore, product specifications are normally left out of quality improvement activities until the process has first been optimized. Once the process has been stabilized, product specifications are compared to process control limits to determine

early to pre vent process from becoming   unstable

if the process is capable of producing the product to those specifications.

Statistical Production Analysis  – X-charts (Shewhart)  – EWMA charts  – CUSUM charts

 – Histograms  – X-Y charts

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System Architecture  The Inform IT Knowledge Manager  offers intranet  solutions that are tailored to meet   your specific requirements.

 Viewer (Web Browser)  Viewer (Web Browser)  Viewer

Thin Clients

Web Server

(Web Browser)

Database and  Application Server

Data Collector

Business Objects

 Application Server

Server and User  Application

Database

Data Buffer

Data Buffer

Data Buffer

 ABB Process Connections

Third Party Connections

Lab Connections

 The Inform IT Knowledge Manager   web-based user  interface brings all server functions to the desktop of the manager. It provides

Knowledge Manager architecture: maximum information availability 

The Application Server, which is where the busi-

Knowledge Manager is built on the new generation

responsible for all server and user applications.

of technologies. It offers open intranet solutions

It provides services such as data integration and

for the acquisition and distribution of plant infor-

consolidation, presentation of information, user

mation. Knowledge Manager is based on industry 

authorization and client access management.

comprehensive and easy to use graphical tools  based on HTML  technology.

ness logic is located, is a software component

standards, ranging from the hardware and operating system (Windows 200x) to the database manage-

The repository for the historical information and

ment (RDBMS). Desktop functions using the familiar

process-based knowledge is the process quality data

 Windows environment and internet standards such

 warehouse managed by the Database Server. Data

as HTML and HTTP are provided. The software has

can easily be kept online for years without archiving.

been developed to support a component structure,

Server hardware performance and storage space is

and its service oriented architecture (SOA) is based

the only restriction for the number and the lifetime

on a model consisting of a Data Collector node,

of data.

 Application and Database Server, and a Thin Client.

The only software that needs to be installed on The Data Collector gathers live data from different

client computers is a web browser. Using this Thin

sources and stores it in the local data buffer. It

Client technology, it is possible to analyze and

uses various protocols, including OPC, to com-

review the collected information from various per-

municate with ABB and other vendor’s control

spectives, generate focused reports to aid manage-

and PLC systems, laboratory analyzers and ERP

ment with informed decision-making, and discover

Systems.

new opportunities by exploring historical and current process and quality infor mation.

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 Application Developer Toolkit  The system soft ware, toolkit and a   web browser allow  the user to immediately start using  the features of the Inform IT Knowledge Manager to its full extent.

Since ABB is well aware that each customer places

On the Thin Client, the user can navigate in an

his own special demands on data evaluation and

intranet, select and view documents, reports and

the acquisition of information, Inform IT Knowledge

graphics, or even make manual entries or modify 

Manager provides a range of easy-to-use configura-

personal reports using a standard web browser.

tion tools.

Run time viewing of configurations, as well as import, export and comparison of configurations

The Application Developer Toolkit is a graphi-

are standard features for authorized users. Business

cal and menu driven configuration tool used to

objects for user authorization, user management,

configure process tags, logs, trends, templates

status monitoring, data retrieval, data processing,

and reports using simple drag & drop editing. For

configuration handling, consistency checking and

example, a user can create and modify templates

enforcement, etc. are also standard. Moreover, the

for intranet documents, reports or graphics from

Knowledge Manager Application Developer Tool-

a comprehensive library of pre-built business

kit embeds various scripting tools for additional

objects. Using this all in one toolkit, a user can cre-

complex processing, treatment of data and advan-

ate and customize displays, reports, trends, manual

ced templates and reports.

entry forms, survey sheets, etc. and make them

Flexibility  is the key: • No specialist  programming  or web development knowledge required  • Toolbox with  pre-configured  elements • Drag & Drop • Copy & Paste

available for other users.

• Full system configuration setup and management  • System customization can   be continued   by customer 

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 ABB InformIT Knowledge Manager

More than 400 installations worldwide are using ABB

InformIT

knowledge-based solutions for information management and

Knowledge Manager is a web-based process informa-

tion management engine based on the 5R principle:

process optimization. As a world leader in process specific

Relevant information is provided at the Right time, at the Right

collaborative production management – ABB is continually 

place, in the Right form, and to the Right people.

developing cutting-edge technology.

 ABB Switzerland Ltd CH-5405 Baden-Dättwil Switzerland Phone: + 41 (0)58 586 84 44 Fax: + 41 (0)58 586 73 33 E-Mail: [email protected] www.abb.com/cement

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