Integration with Corporate Business Intelligence Software

Building upon their success of improving their operations using a global real-time infrastructure for their 70 sites, MaterialsCo focused on integrating PI System data with their enterprise business intelligence systems. To accomplish this, they designed and implemented a standardized method to automatically extract, validate, and transfer data to MaterialsCo's business software suite. This was important because of the following:

  • • The data needed to be extracted, validated, and sent in the correct format for data ingestion. MaterialsCo did not want to send incorrect data, such as when a sensor was unavailable for a period.
  • • These data transfers required manual efforts to extracts, cleanse, and publish the data to their corporate business software and other business analytics tools.

MaterialsCo embarked on using newly released OSIsoft-provided software that is designed for extracting and cleansing PI System data and publishing this data to SAP or to the business analytics software of choice. This software eliminated any custom scripting or programming, as users simply configure what they need to transfer. As a result, MaterialsCo significantly reduced this extraction and cleansing effort from one month to five minutes per transfer. This reduction enabled further collaboration because of the visibility and transparency of data.

Forging Ahead—MaterialsCo Production Management Version 2.0

Based on their success with CPM vl.O, MaterialsCo developed the next set of use cases to further mine the operational data to improve production and operations, and better manage their equipment. Initiated in the mid-2010s, the four major goals of CPM v2.0 were to

  • 1. Develop global quality KPIs by consolidating quality and production data on a single platform to monitor overall quality among the cement plants;
  • 2. Further analyze production data through event frame management for root cause analysis of downtimes and to compare downtimes across the fleet of cement plants, specifically, to record, alarm, and analyze all downtimes to minimize operational impacts and prevent future downtimes;
  • 3. Build a cement plant operation management set of standardized dashboards for operations management; and
  • 4. Incorporate vibration analysis system data into the PI System to assist with their CBM program and enhance CBM efforts by sending equipment alerts to their corporate software's maintenance module.

Perhaps the most beneficial part of CPM v2.0 was to start up a centralized control and monitoring center to support the plants by monitoring fleet operations and production and identify possible problems before they became troublesome. This allowed plant personnel to focus on production and letting corporate engineers solve process or equipment issues before the central team notified them.

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