Production Intelligence
Insight Into Improved Performance ~ Analytical Applications
The real power of Production Intelligence lies in the analytical applications that extract meaningful insight from operational data. These applications, used by operators, engineers and managers deliver actionable views of performance across the enterprise. Sophisticated analytics and predictive models, combined with monitoring and reporting tools, provide real-time decision support systems for plant operators. In-depth analysis capabilities unlock treasures hidden in production data that lead to performance improvement.
Analytical applications fall into four broad categories:
Feed Forward Process Control
Distributed control systems allow operators to monitor continuous processes and react to conditions. Feed Forward Process Control (FFPC) adds a new dimension by equipping operators with tools to anticipate change and proactively make adjustments prior to performance deterioration. It is a series of analytical applications that moves process control from a reactive to a proactive mode. FFPC provides:
- Advanced notice of changes in material
- Standard operating conditions for Key Performance Indicators (KPI's)
- Real-time monitoring of KPI's
- Models that predict deteriorating conditions
Root Cause Analysis
Fluctuations occur in any complex industrial process. They can be a result of unexpected feedstock changes, operator adjustments or even equipment failure. It is critical to quickly understand the cause of these deviations, rectify the problem, and implement standard practices to prevent a recurrence. Root Cause Analysis (RCA) modules provide the ability to trace critical conditions by time stamping events in the process. Rather than simply pointing fingers, cross-functional teams can now collaborate effectively on causes and cures.
Performance Learning
In order to optimize operations, it is important to systematically capture performance results and link them to specific operating conditions. We call this a Performance Learning System. By clearly understanding cause and effect relationships between results and contributing conditions, process engineers can develop operator guidelines that enable superior performance at each step of the process. Production Intelligence provides the framework to capture these relationships and create the guidelines. Process improvement engineers can validate simulation exercises and perform additional "what-if" scenarios to fine tune the process.
Real Time Visibility
Dashboards and scorecards have emerged as one of the most effective ways to monitor the performance of an organization. Production Intelligence brings this capability to key stakeholders in the production process by providing real-time feedback on performance issues. Rather than relying on outdated production records reporting on how things were, production managers gain improved visibility into how things are. They are now equipped to contribute to strategic and tactical decisions that will positively impact production. Production Intelligence provides highly customizable, interactive dashboards, scorecards, graphs and reports for superior plant performance management.
