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© 2012 IBM Corporation
Globales Anlagenmonitoring und analytische Datenauswertung in der Produktion zur Erhöhung der Produktivität und zur Verbesserung der Planung
Hannover Messe International - Vortrag 25. April 2012
Ralf Thiemann , Lothar Zügel
© 2012 IBM Corporation
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Agenda 25. April 2012 11.30 – 12.00
Analyse , Optimierung und Verarbeitung grosser Datenmengen
Voraussetzung Integration
Projekt Beispiel – Globales Monitoring und Daten Analyse von Windparks
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2
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Referenz Projekt – Effizientes Energie und Ressourcen (Wasser) Management 5
Diskussion und Fragen ?6
Ansätze , Methoden und Werkzeuge 1
© 2012 IBM Corporation
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Ansätze , Methoden und Werkzeuge zur Produktivitätssteigerung und Transparenz
• U.a Sensor Echtzeit Daten und Zählerstände
Data Data
Data ModelingData Modeling
Visualization &Decisions
Visualization &Decisions
Sensors and Metering
Event Processing + RealTime Data Integration
Data Predictive + Historical
Analytics
New Data
New Insights
ProcessInnovation
Data Modeling
Visualization &Decisions
Visualization, Rules &Collaboration
New, Optimized Businessand Lifecycle Processes
• Ereignis Verarbeitung und Visualisierung aus unter-schiedlichen heterogenen Quellen
• Statistische Analyse und Korrelation von Ereignissen und historischen Quellen zur Entscheidungsunterstützung
• Nutzen in Anwendungen und Unternehmensweiten Prozessen
• Visualisierung der Information in rollenbasierten Portalen mit hinterlegten Geschäftsregeln
Advanced Condition Monitoring:
Predictive Asset Management :
Entscheidungsunterstützung durch Vernetzung mit Daten aus Produktionsssystemen zur statistischen Analyse
Statistische Modellierung historischer und aktueller Daten zur vorausschauenden Planung und Fehlererkennung.
© 2012 IBM Corporation
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Smart Equipment (high value assets) Data Collection/On boarding Systems,
Workflow, Value-added Semantic Reference Models, Rules engine (Jrules), Event/action , ETL, Application Integration, ...
Production
OptimizationPerformance
Management
Voraussetzung ist die Intelligente Vernetzung der Unternehmens- und Planungssysteme mit der Produktion
Decision Support System ,Rollen basierte Cockpits , ERP, …
AC
Business
AnalyticsOperational
Effectiveness
Equipment
AnalyticsAsset Effectiveness
Ressource
EfficiencyWater, Energy,
Materials...
Integrated Data Platform (Integrated Information Core / IIC)
Weitere Anwendungen
© 2012 IBM Corporation
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Statistische vorausschauende AnalysePredictive Analytics System• Analytics for ‘through the windscreen’ view . • Predictive insights improve management and refine business rules
BI System• For reporting from asset mgt system and for
distribution of predictive analyticsinsights which have opeartional significance
ActionableInsights
Asset Management System• Powerful ‘rear view mirror’ data source for Monitoring,
Reporting & Managing based on past and very recent events• Maintenance planning tool integrated within PAM and ACM
Planning Insight
ACM Pro-Active Response• For alerting maintenance to
forecast alarm / risk conditions• For identifying near term
preventative interventions
Real TimeInsights
© 2012 IBM Corporation
6 © ILOG, All rights reserved
Optimierung hilft Entscheidungen zu verbessern
What-If Analysis
Collaboration
© 2012 IBM Corporation
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Verarbeitung grosser (un)strukturierter Daten Mengen aus heterogenen und verteilten Systemen
IBM Confidential
Applications
InfoSphereInformation Server
Business Analytics
Predictive Analytics
Data Warehouse
InfoSphereStreams
Event detection and capture of real-time data
BigInsights
Volumes of raw data (structured and unstructured) in file systems (often highly distributed)
Real-time streamingdata (structured andunstructured)
Traditional data sources(ERP, CRM, databases, etc.)
Operational
Data Store
Real-time analytics
Analytics on
Big Data at rest
© 2012 IBM Corporation
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Agenda 25. April 2012 11.30 – 12.00
Analyse , Optimierung und Verarbeitung grosser Datenmengen
Voraussetzung Integration
Projekt Beispiel – Globales Monitoring und Daten Analyse von Windparks
3
2
4
Referenz Projekt – Effizientes Energie und Ressourcen (Wasser) Management 5
Diskussion und Fragen ?6
Ansätze , Methoden und Werkzeuge 1
© 2012 IBM Corporation
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Renewables Transformation Path
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Optimize- e.g. Predictive Analytics
Mat
urity
Time
Manage- e.g. Condition-based Maintenance
Monitor- e.g. KPI’s, dashboards
2010
Increase in effectiv
e
Power Syst
emes integration
2015 2020
© 2012 IBM Corporation
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Asset and Power Generation Optimisation:• Asset Optimization & Component level inventory management on global level• Proactive spare parts management• Asset Insurance management• Speedy emergency response • Energy Scheduling and Load Forecasting
Business Performance Management & Analytics:• Operational and Business KPI reporting in real-time• Optimized Power Prediction and input to trading• New project planning, scheduling and tracking• Predictive Maintenance & optimised Shutdown Planning• Energy Accounting & Production Cost Calculations
Remote Monitoring and Control:• Global, Regional, Site, Turbine, Sub-Station level real-time monitoring & Control • Automated event based error handling• Shared Service Platform across geographies• Curtailment Tracking
Technical Excellence and Procurement:• Uncover trends, patterns from turbine errors• Historical Analysis of Turbine performance• Modelling and Simulation of optimal site location based on historic wind directions• Comparison of actual power curves w.r.t. to OEM power curves
Plattform Scope
© 2012 IBM Corporation
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Management BetriebPlanungs Team
MonitoringGlobal Regional Site leve Regional
Management Report & Analytics
Turbine Site ScheduleControl
Unified Information Model
‘N’
WeatherForecast
MarketPricing
WorkforceMgmt.
Projekt Zielsetzungen
© 2012 IBM Corporation
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Reference case study – IBM BurlingtonAdvanced Water & Energy Management
• Challenge–Reduce water consumption (and associated need for energy, chemicals, maintenance and labor) to reduce operating cost and minimize environmental impacts
• Approach– Implemented data collection and storage
infrastructure: sensors, IT network and servers– Statistical process control techniques used to
continually analyze vast amounts of operational data and present information in efficient, concise interface
– IBM’s Green Sigma methodology breaks down water usage by process:
– Dashboards convey key process indicators– Identifies process improvements that reduce
water consumption and provide other benefits, such as reduced electrical power consumption,
•Results•IBM has achieved over $3.6M in annual savings, reduced water usage by 27% while increasing manufacturing capability over 30%
IBM 200 mm Wafer Fabricator
© 2012 IBM Corporation
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Advanced Sensors
Existing SCADA
Control Devices
Disparate Data Sources
Maximo
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Burlington Advanced Water & Energy ManagementpH, RO Feed X-Bar S Chart, 1 Day
Strt Date: 1/6/2009 DI Central, SPCEnd Date: 1/7/2009
Method: Modified Control LimitsData: 96 subgroups of 15 samples, 1 min. rate
Status: Operations
Common Carbon Outlet Flow
0
500
1000
1500
2000
Booster Pmp Dis. Pres.
0
50
100
150
200
SPC X-Bar Chart: pH, RO Feed
4.004.204.404.604.805.005.205.405.605.806.00
1/6/0900:15
1/6/0902:15
1/6/0904:15
1/6/0906:15
1/6/0908:15
1/6/0910:15
1/6/0912:15
1/6/0914:15
1/6/0916:15
1/6/0918:15
1/6/0920:15
1/6/0922:15
Subgroup Time
pH
Xbar
UCL
LCL
USL
LSL
Com
SPC Sigma Chart: pH, RO Feed
00.10.20.30.40.5
1/6/0900:15
1/6/0902:15
1/6/0904:15
1/6/0906:15
1/6/0908:15
1/6/0910:15
1/6/0912:15
1/6/0914:15
1/6/0916:15
1/6/0918:15
1/6/0920:15
1/6/0922:15
Subgroup Time
Std Dev
StdDev
UCL
LCL
RO Feed pH
0
2
4
6
Integrated Information Framework
Asset Mgmt.
Visualization and Optimization
Event Mgmt.
Modellingand Analytics
EmergencyResponse
© 2012 IBM Corporation
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Diskussion und Fragen
???
KontaktRalf Thiemann , [email protected] , 0170 7851257Lothar Zügel , [email protected] , 0172 6730305
