best practices in port automation - osisoft · 2019-06-20 · best practices in port automation •...

© Copyright 2019 OSIsoft, LLC

Best Practices in Port AutomationMatt MillerJune 19, 2019


Introduction

Matt [email protected] Industry Principal

mailto:[email protected]


Webinar Topics

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Who is OSIsoft?

Future of Smart Ports

Best Practices in Automation

Learning From Other Ports

Q&A


We BELIEVEPeople with DATACan TRANSFORMTHEIR WORLD

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© Copyright 2019 OSIsoft, LLC 8

Assets

MultipleSensors

Plant

MultipleAssets

Enterprise

MultiplePlants

Community

MultipleEnterprises

Sensors

Millions of Smart Devices

OSIsoft’s Strategy: From Sensors to Community

© Copyright 2019 OSIsoft, LLC© Copyright 2019 OSIsoft, LLC 9

Where Do Transportation Companies Find Value?OPERATIONAL

PERFORMANCERESOURCE &

FUEL MANAGEMENT

ENVIRONMENTALREPORTING & COMPLIANCE

ASSET HEALTH & RELIABILITY

• Fuel Optimization

• Water Conservation

• Energy Management

• Governmental Regulations

• Accident & Incident

• Emergency Response

• License to Operate Parameters

• Improved uptime

• Condition-based maintenance

• Asset Utilization & Depreciation

• Reduced Maintenance Costs

• Network capacity & throughput

• On-time arrivals• Capital

effectiveness• Operating

certifications• Automation


Business Outcomes Enabled by the PI System

OPERATIONAL PERFORMANCE

& CAPACITY

RESOURCE & FUEL

MANAGEMENT

REGULATORY COMPLIANCE

ASSET MANAGEMENT &

RELIABILITY

http://www.caterpillar.com/



Select Transportation Customers

Rail Marine Trucks Ports



APPLICATIONS & ANALYTIC TOOLS

The PI System is a Real-time System of Recordfor Critical Operations

DATA SOURCESAutomation Systems

IoT Gateways

Control SystemsRemote Sensors & Assets

PEOPLEProcess EngineerProduction ManagerReporting AnalystOperations ManagementData ScientistMaintenance Engineer

Real-time Monitoring

Analytics, GIS, BIG Data

Specialized Applications

3rd Party Services


The PI System for Ports


It’s Time to Find a New Way to Work

Operational Excellence

Operational Performance &

Capacity Increases

Resource & Fuel Optimization

Asset Management &

Reliability

Regulatory Compliance

“Catastrophic machines failures are much more expensive than planned downtimes.”

© Copyright 2019 OSIsoft, LLC 18© Copyright 2019 OSIsoft, LLC 18

Future of Smart Ports


The Future of Transportation is…Intelligent!

Connected

Sustainable

Collaborative

Automated

Electrified

All Driven by Real-time Data!

© Copyright 2019 OSIsoft, LLC20

Operational Excellence

Digital Transformation Unlocks New Opportunities

ProductInnovation

New Services

IncreaseRevenue

DigitalTransformation

ReduceCosts


Smart Port Challenges

• Increasing volumes – 400M ton/year globally*• $10B Automation investments are decreasing throughput!**• Environmental Compliance Pressure• Asset and Energy Intensive – long return on capital• Intermodal Price Pressure• Greater transparency to all stakeholders - Collaboration

*Source UNCTAD 2018 Review of Maine Transport** Source 2019 McKinsey The Future of Automated Ports Study


Smart PortsDigital Transformation

o Lean Approacho Perfect Order= Perfect Movemento Digital Maturity Model & Metricso Value Focused


Block Chain Operational Use Cases

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Asset lifecycle and history

Parts history

Maintenance/repair history

Events

Transfer of ownership

Supply chain

Ingredients

Manufacturers

Trackability / Traceability

Temperature controlled supply chains

Data

Provenance / Quality

Ownership

Monetization


Blockchain Integration Partnerships

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+


Realtime Data

Economy


ManufacturerTestingSales

Logistic partnersCustomsFreight forwarders

Commissioning partnerCustomerTesting

Service departmentService partner

Supplier

DecommissioningRecycling partner

LegalNew owner

Testing


The Future in the CloudOSIsoft Cloud Services

Connected Community

Data Science Enablement

Partner AppsPlatform

Remote Ops Monitoring


Best Practice Steps


Best Practices in Automation

BASELINE YOUR OPERATIONS

BUILD A REAL-TIME OPERATIONAL SYSTEM

OF RECORD (SOR)

OPTIMIZE THE PROCESS FOR A "PERFECT

MOVEMENT"

PLAN FOR EXCEPTIONS NURTURE DATA ECOSYSTEMS

DATA DRIVEN

CULTURE


Baseline Operations

Collect the data first to know where you started Identify priorities and best investmentsRefine operating model (Digital Twin) Track phases of operation through the processAlign metrics and tactics with business strategy


Building a Real-time Operational SoR

Capture in original fidelity from as many sources as possibleData abstraction layer between business and operationsOne version of the operational “truth”Place to address data quality issuesSecure access to control and safety critical systemsManaged by Operations administered by IT


Optimize for the Perfect Movement

Analyze phases to determine where time is lostMeasure against plan in real-time Identify constraints Remove or reduce themRepeat…Automate


Plan for Exceptions

Meet the challenges of digitalizationConsistent asset integration across the enterprise Enable advanced analytics – prescriptive & predictiveIntegrate with other business systems of record

Consider Optimized Operational Envelopes Repeatable route segments using many assets Better understanding of activities and best practices Optimization tuning dependent on current goals (on-time, fuel, safety, wear)

Identify top risks to delivering expected outcomes and innovate!

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Nurture Collaborative Ecosystems

•On-time arrivals•Shorten lead-times•Resiliency•Reduce Waste/Cost•Lower risk•Emergency Management


Data Drive Cutlure

Empower all stakeholders with data for better decision makingMake it self-serve as much as possible Focus on who’s solution is bestNot who’s data is right


Learning From Others

© Copyright 2019 OSIsoft, LLC“ ”

Port Information Management

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Unreliable access to asset data

Inefficiencies in fuel use and maintenance

Difficulty meeting compliance and capacity requirements

The PI System as a real-time, common data infrastructure across ports, vessels, cranes and terminals

Reduced fuel consumption, maintenance costs and downtime

Increased port throughput, revenue, and profit margins

CHALLENGES SOLUTION BENEFITS

The PI System integrates all our equipment data at the enterprise level. That helps us increase productivity and preserve the profitability

of our ports. Pradeep Gupta, Project Director, Adani


Operations before Implementation

Share planning with stakeholders

VTMS - Vessel at Anchorage

Berth planningDischarge sequence & Sub

sequence planning

Allocate Assets

Tugs boats –Anchorage to Berth

Actual Discharge Monitoring

Capture delay and stoppage reasons

Capture and share breakdown of assets

Forecasting of Vessel & Material

Re arrange the plan as per available assets

Monitoring deviations in plan

Monitoring movable assets & Safety

Reporting on asset performance


Operations after Project Implementation

Forecasting of Vessel & Material

Tugs boats –Anchorage to Berth

Capture delay and stoppage reasons

HMI

West Basin

FMS

WB WLS / TLS

VTMS

• Berth planning• Discharge Sequence & Sub

sequence Planning• Allocate Assets• Monitor Plan Vs Actual• Replan

Share planning with stakeholders

DVMS

Safety Assets

Weather

Advance QueuingVehicle Route PlanningSupply Chain Optimization

Planned


Equipment Logistic Strategies

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Port needed to support additional 10 Mt increase of throughput without any capital expenditure

The PI System isan information hub that managesall aspects of the supply chain, including KPI-based planning and predictive maintenance

Increased shipping capacity from 16 Mt to 26 Mt with no infrastructure investments

Increased capacity meant $120M of additional revenue in 2015


All of the information is available to everyone. Absolutely no limitation. Everybody from the shift operator all the way to the CEO is looking at

the same data and information is plastered everywhere.Michel Plourde, Director of Systems, ArcelorMittal

Mines Canada


Time Usage Model - A Practical Implementation

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Production

Production time

Production target

Startup Shutdown

Reduction

Operating = Process/Eqpt providing at required levelDelayed = Equipment not providing service level requiredStopped = Equipment/Process idleDown = Equipment brokenMaintenance = Scheduled Maintenance


One Information Source for Optimized Supply Chain Planning

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Improved Shipping Container Operations

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Inadequate tools and data for detailed process analysis

Disparate datasources that were not structured for quick insight

Integrated PI System with container-terminal systems to improve awareness

RMG Cycle Time decreased by more than 10%

Increased Maintenance Compliance: 100% on target


With the transition towards using PI to collect that data, not only do we save manpower in manually collecting readings, but the accuracy

and the repeatability of those readings is significantly improved.Mark Jensen, Assistant VP of Equipment and Facility Maintenance, TraPac

#OSIsoftUC #PIWorld ©2018 OSIsoft, LLC#OSIsoftUC #PIWorld ©2018 OSIsoft, LLC

Objective: Improve operational efficiency of RMG by improving travel times for its movements

Use Case: Improved Operational Efficiency –Optimizing RMG Travel Times

Automation Transfer Area


Divide the RMG cycle into phases based on crane movement, job status, remote operator status, transfer area reservation status


Move to Pick Location

Pick container

Move to Ground Location

Ground container

Horizontal

Lateral

Vertical


Used Event Frames to quantify duration of each phase and create a baseline to help identify outliersResults• Quantified idle time crane movements

which provided necessary data to support programming changes to RMG PLC

• 10% improvement in cycle times



Objective: Leverage PI System to expedite troubleshooting

• Problem reported as significant reduction in RMG throughput

• Initial suspicions pointed to recent control-system update

• Problem was intermittent and visual inspection was inconclusive

Use Case: Expediting Issue Resolution


Results

• Quick visual recognition of typical spreader profile versus bad

• Worked with mechanics to pinpoint issue – bent spreader flipper, distortion undetectable

• Without PI data, would be guessing at issue

• “Unless we went out there with a straight edge, we may still be searching for the cause!”

Use Case: Expediting Issue Resolution

BAD

GOOD

Moving to Pick Location

Smooth change in hoist direction

Hoist is “bouncing” to pick container

Pick Attempt


Objective: Leverage PI System to digitalize maintenance workflow and improve maintenance interval compliance

• PI AF configured to send email to third-party CMMS daily using PI Analysis, PI Event Frames and PI Notifications

Use Case: Improving Maintenance


Use Case: Improving MaintenanceStraddle Carrier• Automated container transport

vehicle• Travels freely between equipment• Operates in fenced-off automated

area• Breakdowns may not be addressed

until work stoppage


Results: Data provided by PI System helps drive the PM maintenance regime within our CMMS, particularly for meter driven PM, resulting in a significant upward trend in PM creation



Results: Timely and accurate data has resulted in a significant shift in compliance to PM schedules

• Autostrad PM is typically based on a 200 hrs inspection and a hierarchical 1,000 hrs service interval.

• Actual intervals against this target have been tracked for gauging PM Schedule Compliance.

• PM Scheduling compliance: -0/+10%: on target. -0/+5%: considered hitting the bullseye.


#OSIsoftUC #PIWorld ©2018 OSIsoft, LLC

Interval Count of Interval % <950 76 48%950-999 11 7%1000-1049 17 11%1050-1100 12 8%>1100 42 27% Total Count 158

PM Schedule Compliance – 1,000hrs servicingPrevious method – prior to Jun 2017

PM Schedule Compliance 1,000hrs servicingNew method –Since Jan 2018

11% bullseye19% on target

More data is desirable before declaring an outstanding success but the indicative trend so far is very favorable.

The new method supported by PI sees good accuracy and repeatability for the 200hrs inspections interval. The previous method never captured 200hrs inspection data for comparison.


80% bullseye100% on target

Interval Count of Interval % 1000-1049 28 80%1050-1099 7 20%Total Count 35


Best Practices in Port Automation• Key to Smart Ports is driving value added digital

transformations

• Real-time Operational System of Record supports scale & time to value

• Follow cross industry best practices and steps

• Collaborate through data communities


• Go to our website

• www.osisoft.com\transportation

• Email me [email protected]

• LinkedIn

Want more information?

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http://www.osisoft.com/transportation

mailto:[email protected]


THANK YOU

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best practices in port automation - osisoft · 2019-06-20 · best practices in port automation •...

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