IndustrialIT: Performance Management for the Cement Industry

InformIT Knowledge Manager

InformIT Knowledge Manager

All production knowledge at your fingertips. You need easy access to timely, accurate, reliable information in order to enhance enterprise-wide productivity.
Profitability

Best Practice
Dispatch Automation Solutions

Experience

Real-Time Performance Monitoring

Knowledge Manager
Production Accounting SAP Integration

Knowledge

SAP
Microsoft Excel AutoLab Quality Robotics

Statistical Production Analysis

Production Information Management

Excel Add in
LIMS

Process Data Management Raw Data

Process Control

Raw Data

Knowledge Manager: Maximizes the economic performance of your assets Enables you to reach environmental, production and quality goals Supports the achievement of quality management by integrating process, production and quality information Supports defined work processes and ensures manpower efficiency by delivering relevant operation information for improved decision making

Produce quality products more effectively

Effective production management
If you have the specific information you need at the right time and the right place in the right format, your decisions will be more goal oriented, and you will be able to optimize processes and increase productivity. With Knowledge Manager, part of ABB's InformIT application suite, you have the solution and advanced tools you need to facilitate the collection, organization and distribution of production and quality information throughout your plant organization.

Modular design
The core of Knowledge Manager comprises all the functions and components needed for industry specific process and quality data warehousing and focused information presentation. Knowledge Manager can be adapted and expanded to meet each company's specific requirements, and can incorporate up to several hundred users in order to keep pace with growing demand.

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 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 Information Management drastically simplifies production management, covering production related functions like: production tracking and reporting process operations monitoring and reporting material storage management, and energy and emission reporting. Identifying the influences that process parameters have on product quality, production capacity, energy consumption and emission levels is now easier than ever. Powerful analysis tools are available at the click of a mouse button. After all, successful process information is key to your plant operation. The Knowledge Manager production management functionality includes running plant overview and specific calculating and reporting capabilities for production, material storage and emissions. The key to production planning is the online access to information without delays. Knowledge Manager provides reliable reports on the plant production situation: product stocks, capacities of process equipment, availability, etc. Better utilization of energy, equipment, inventories and capacities can be expected. Process operation support helps process managers identify the influences that process parameters have on product quality, production capacity, etc. It combines production related data, process variability, energy indexes, run-time quality parameters, etc. in comprehensive process operation reports. Connectivity to ERP systems (SAP, BAAN, PeopleSoft, etc.) is nowadays an essential tool to bring production data from floor level to enterprise management level. Knowledge Manager serves here as the information broker between the realtime control and production environment and the transactional based ERP systems. With Knowledge Manager, production and process managers become empowered knowledge workers.

Fast and informed decisions: Increased production through best-in-class work practices, greater focus and deeper understanding Real-time manufacturing performance and target monitoring for continuous improvement

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 not. Reducing downtime and keeping up production capacity is vital for any production plant. And correct information is the key. The Knowledge Manager Downtime Management and Maintenance Support solution ensures you know for certain what your most costly problems are, taking the guesswork out of maintenance by integrating facilities for easy identification of failing equipment. Pareto analysis is used to find out the real and most costly weak points in the production process and provides support for forecasting the next maintenance event. Identification of failing equipment is based on event and alarm statistics. Results are issued daily/weekly in e.g. TOP TEN forms. Maintenance events of specific process equipment are forecasted by using equipment running hours, production totals, cumulative energy utilization, etc. Pareto analysis is based on configurable causes based on a plant definable fishbone diagram. Reliable statistical information on downtime causes is the basis for corrective action. The information is essential for justification of capital expenditure, personnel training, etc. Direct integration of information into your ERP (Enterprise Resource Planning) system is an obvious advantage. Transferring stop logs, running hours, downtime statistics, etc. to SAP's PM and PP module, is a matter of plug and play. It eliminates the work of the manual input through the SAP GUI. Although automatic, it allows for validation, manual correction and approval by the maintenance and production manager before transfer. Through interfaces like these, we protect your long-term investments by making use of industry standards.

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 activities are usually focused on the month-end closing and on the day-to-day administration of materials, consumption and efficiency. The regular challenge of making production results coherent and consistent is drastically simplified and sped up with Knowledge Manager's Cement Production Accountant. In the Knowledge Manager environment, all the required data is automatically collected from the different subsystems on the plant such as process control systems, the dispatch system, sales administration and so on. The data is then rolled-up and calculated into a one-page overview. Detected discrepancies between figures are highlighted. You can then drill down into each of the results to consult the data hierarchy, the calculations and the input data that produced the particular result. Data can be adjusted and the new results previewed. Knowledge Manager automatically takes care of the reconciliation of related data so that the database remains consistent. Any further reports will show figures that are consistent with previous reports. For systematic and re-occurring adjustments, variable factors can be applied on the source data. When the factors are adjusted systematically, a learning effect is achieved and the relative discrepancies will minimize over time. Historical analysis of the correction factor schemes provides valuable information to minimize accounting efforts. Further improvement is achieved in the automated day-to-day administration of materials. By using advanced stock tracking mechanisms, available data is automatically calculated. The latest and best possible estimates of non-instrumented storage locations such as stockpiles and bulk silos are provided.

Production data inevitably require balancing and reconcilation before reporting.

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

Excel Add-In

Information available in Excel

Having an impromtu meeting? Use extensive Excel tools to provide: Additional KPIs Performance reviews Budget plans Cement quality reviews and forecasting Process models and studies

Ad hoc reporting quickly

Sourcing the right information from everywhere, manually typing it in, transferring it to the right format, etc. for a report that had to be ready yesterday? The Knowledge Manager Excel Add-In makes user specific ad hoc reporting much easier. You can run queries directly from the Excel spreadsheet without the need to write SQL queries. You simply select the data required. With underlying direct web queries, the data is retrieved from one or more servers simultaneously. Thus the production information is available for further processing and formatting with standard Excel functions. Importantly, this bi-directional link can easily be used for bulk data correction in Knowledge Manager.

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? MM/SD

SAP
PP-PI PM Production, Material and Energy Consumption Production, Orders, Deliveries, Goods Received Production Information Manager

Applications: Production costing Production planing Material management Plant maintenance Extensive KPIs

Management
Operations Production Sales Maintenance Quality

Knowledge Manager
Production Accounting Process Data Management Control System Manual Entries Laboratory LIMS

How is the plant performing?

Extend your knowledge by integration with your SAP System

The Knowledge Manager SAP Connector extends the reach of Knowledge Manager into enterprise applications by supporting the direct interaction between the manufacturing processes with SAP ERP software. Using this connector, the manufacturing information integrates with the SAP; and the business information from SAP integrates to the manufacturing environment in a smooth and accurate way. All the methods required for connecting to SAP and transferring the manufacturing information are fundamental to the Knowledge Manager SAP Connector. The engineering and configuration of the SAP connector is done through the Knowledge Manager Application Developer Toolkit, i.e. the same tools and methods used for report configuration are used to configure the SAP Connectors. No specific knowledge of the SAP internals, or SAP interface technologies, and most importantly no knowledge of software development is required to use or configure the connectors. On SAP no specific customization is required in most of the modules; the Knowledge Manager SAP Connector replaces the 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 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: Benefit from unique, seemless and full integration of information Visualize and better understand the relationship between process conditions and quality results

Integrate laboratory management with enterprise-wide production

InformIT Knowledge Manager LIMS covers all laboratory tasks for the entire process and issues compliance certificates. Naturally it's fully integrated with enterprise-wide process and production monitoring, downtime support and maintenance management. 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 Manager LIMS provides the foundation for direct process management and process quality control on a day-to-day basis. It is designed to enhance process improvements and to provide a firm basis for your further production. Included are functions such as automatic and manual data acquisition, data validation, data consolidation, long-term storage, calculations, sample logging procedures, sample status reports, work lists, standard and compliance reporting features, easy-to-use trending and graphing plus options for Excel and statistical analysis applications.

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 causes before out-of-specification product is produced. In InformIT Knowledge Manager Statistical Production Analysis, the trend functions X Chart, EWMA chart and CUSUM chart have been selected to match manufacturing process specific requirements. The X-Y graphs provide the facility to plot two variables against each other to see the possible correlation between them with automatic compensation of time delay. Histograms allow for readable statistics of run-time quality measurements. In SPC, the quality is emphasized as a process characteristic. If the process is controlled and improved, product quality will be maximized automatically. 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 if the process is capable of producing the product to those specifications. Statistical process control charts contribute to process and quality improvement: They provide a picture of the condition of the process and the improvement of the quality over time; They provide information for correction of causes and for improvement of the process; They indicate the process capability what it is actually capable of doing during attributable cause correction and process improvement activities.

Statistical Production Analysis provides powerful tools to: Effectively monitor quality related process variables Verify if the variables are randomly scattered around the mean and normally distributed Detect changes in variability and determine changes in the process average early to prevent process from becoming unstable

Statistical Production Analysis

X-charts (Shewhart) EWMA charts CUSUM charts Histograms X-Y charts

System Architecture
The InformIT Knowledge Manager offers intranet solutions that are tailored to meet your specific requirements.
Thin Clients

Viewer (Web Browser) Viewer (Web Browser) Viewer

Web Server

(Web Browser)
Database and Application Server
Business Objects Application Server

Database

Server and User Application

Data Collector

Data Buffer

Data Buffer

Data Buffer

ABB Process Connections

Third Party Connections

Lab Connections

The InformIT Knowledge Manager web-based user interface brings all server functions to the desktop of the manager. It provides comprehensive and easy to use graphical tools based on HTML technology.

Knowledge Manager architecture: maximum information availability Knowledge Manager is built on the new generation of technologies. It offers open intranet solutions for the acquisition and distribution of plant information. Knowledge Manager is based on industry standards, ranging from the hardware and operating system (Windows 200x) to the database management (RDBMS). Desktop functions using the familiar Windows environment and internet standards such as HTML and HTTP are provided. The software has been developed to support a component structure, and its service oriented architecture (SOA) is based on a model consisting of a Data Collector node, Application and Database Server, and a Thin Client. The Data Collector gathers live data from different sources and stores it in the local data buffer. It uses various protocols, including OPC, to communicate with ABB and other vendors control and PLC systems, laboratory analyzers and ERP Systems.

The Application Server, which is where the business logic is located, is a software component responsible for all server and user applications. It provides services such as data integration and consolidation, presentation of information, user authorization and client access management. The repository for the historical information and process-based knowledge is the process quality data warehouse managed by the Database Server. Data can easily be kept online for years without archiving. Server hardware performance and storage space is the only restriction for the number and the lifetime of data. The only software that needs to be installed on client computers is a web browser. Using this Thin Client technology, it is possible to analyze and review the collected information from various perspectives, generate focused reports to aid management with informed decision-making, and discover new opportunities by exploring historical and current process and quality information.

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Application Developer Toolkit

The system software, toolkit and a web browser allow the user to immediately start using the features of the InformIT Knowledge Manager to its full extent.

Since ABB is well aware that each customer places his own special demands on data evaluation and the acquisition of information, InformIT Knowledge Manager provides a range of easy-to-use configuration tools. The Application Developer Toolkit is a graphical and menu driven configuration tool used to configure process tags, logs, trends, templates and reports using simple drag & drop editing. For example, a user can create and modify templates for intranet documents, reports or graphics from a comprehensive library of pre-built business objects. Using this all in one toolkit, a user can create and customize displays, reports, trends, manual entry forms, survey sheets, etc. and make them available for other users.

On the Thin Client, the user can navigate in an intranet, select and view documents, reports and graphics, or even make manual entries or modify personal reports using a standard web browser. Run time viewing of configurations, as well as import, export and comparison of configurations are standard features for authorized users. Business objects for user authorization, user management, status monitoring, data retrieval, data processing, configuration handling, consistency checking and enforcement, etc. are also standard. Moreover, the Knowledge Manager Application Developer Toolkit embeds various scripting tools for additional complex processing, treatment of data and advanced templates and reports.

Flexibility is the key: No specialist programming or web development knowledge required Toolbox with pre-configured elements Drag & Drop Copy & Paste Full system configuration setup and management System customization can be continued by customer

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ABB InformIT Knowledge Manager

InformIT Knowledge Manager is a web-based process information management engine based on the 5R principle: Relevant information is provided at the Right time, at the Right place, in the Right form, and to the Right people.

More than 400 installations worldwide are using ABB knowledge-based solutions for information management and process optimization. As a world leader in process specific collaborative production management ABB is continually developing cutting-edge technology.

ABB Switzerland Ltd CH-5405 Baden-Dttwil Switzerland Phone: +41 (0)58 586 84 44 Fax: +41 (0)58 586 73 33 E-Mail: process.industries@ch.abb.com www.abb.com/cement

3BHS 128037 ZAB EO1 Rev A (07.05. 1000 Pomcany's)