The Plant Operations System Data Archive is the foundation of this system. It handles the collection, storage, and retrieval of numerical and string data. It also acts as a data server for Microsoft Windows-based client applications. Operators, engineers, managers, and other plant personnel use these client applications to view the plant data stored in the Plant Operations System Data Archive.
Plant Operations data can be used for plant and corporate initiatives such as process improvement, total quality control, and predictive maintenance. The unified plant data repository ensures that all individuals view and analyze the same data. Software applications such as maintenance management, expert systems, and optimization/modeling programs can use Plant Operations to gain access to real time data.
The Plant Operations System can link real time control systems to production planning systems and enterprise resource planning systems to bridge the gap between business and real-time production environments.
The Plant Operations System is designed to be easy to install, maintain and use. Inexpensive migration paths that preserve the existing plant historical data are provided to update legacy PI systems to the Windows NT based technology. New features are extensively tested for compatibility with older versions.
Lower Production Costs: The Plant Operations System's data analysis and graphical tools permit problems to be resolved faster, and often prevent small conditions from becoming major upsets. Many companies report that the data stored in Plant Operations allow them to improve their preventative maintenance programs, increasing equipment life. These uses result in increased production and lower operation costs. In addition, the Plant Operations System contributes to yield improvements and less waste. When the lab system sends massages to operation via the Plant Operations System, for example, the time required to change grades decreases, increasing production and minimizing waste.
Higher Product Quality: The time to respond to a quality problem is before the product goes out of spec. Applications such as the PI-Profiles package allows inconsistencies to be noticed and fixed before they become serious problems. Operators also appreciate the Plant Operations System because they can review operation conditions from previous runs, a valued feature when producing unusual or difficult product grades.
The Plant Operations System provides an easy-to-use mechanism for obtaining and monitoring continuous process improvement. These programs frequently lead to improved quality with no increases in production costs.
Better Customer Service: With access to a Plant Operations System, customer service and quality assurance groups can quickly respond to customer complaints and concerns about product quality. This is because process data are stored at high resolution and remain online for extended periods of time. Personnel are also able to analyze past data to determine whether requests for new grades or products specs are feasible. And, because current data are also available, sales teams can review process conditions to determine when a new order cam be scheduled or delivered.
Increased Productivity and Improved Process Knowledge: Less time is wasted trying to obtain data and information relating to a problem, so more time is available for solving it. Everyone throughout the facility uses a common set of data, eliminating discussions of whose data set is "right", again contributing to a more productive use of everyone's time. Also, application developed internally with the Plant Operations System, such as performance monitoring and efficiency calculations may be shared between sites, reducing development time.