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Process visibility and PV value chain optimization
 

Process visibility and PV value chain optimization

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High-level presentation of solutions for optimizing PV manufacturing processes through increased process visibility

High-level presentation of solutions for optimizing PV manufacturing processes through increased process visibility

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  • Key facts about Prediktor. We were established in Fredrikstad in 1995. That is where we have our headquarter. Our main business is within industrial IT solutions and consulting services for PV manufacturers. We have 7-8 years of experience with PV manufacturing. Like most Norwegian companies Prediktor is probably, in Chinese eyes, not very impressive when it comes to size. We have less than 100 employees. However, we are extremely specialized and leading within the area we focus: advanced industrial IT solutions and consulting services for the optimization of solar PV manufacturing operations. We undertake and participate in highly specialized research and development projects to support the optimization work undertaken by our customers. The target is to make solar energy a competitive and sustainable alternative to oil and coal. PV scientists, process optimization experts and software engineers work together to optimize PV manufacturing processes. We cover the complete value chain from raw-material to complete product.

Process visibility and PV value chain optimization Process visibility and PV value chain optimization Presentation Transcript

  • Agenda
    Process visibility and
    PV value chain optimization
    27. May 2010
    Henrik Hassel
    Managing Director,
    Prediktor China
  • 多晶硅材料
    silicon
    硅片
    wafer
    硅锭
    ingot
    电池
    cell
    组件
    module
    PV 电厂
    Power plant
    Solar PV production chain
    • Reduce costs
    • Improve quality
    • Increase throughput
    Goal: more solar energy at continuously lower costs!
  • 硅片
    wafer
    Sample case, wafer production
    High proportion of
    wafers with unacceptable
    resistivity levels
    ....
    • What do these wafers have in common?
    • What is the root-cause behind this?
    • How can we find out as fast as possible?
    • What corrective actions do we need to take?
    • All wafers come from bricks produced in line #3, furnace #2
    • This furnace has high deviation in energy consumption
    • Production is stopped, maintenance checks furnace #2
    • Gas leakage identified and fixed
    • Problem solved, production resumes as normal
    #2
  • Brick position of defect wafer
    The entire production history
    of each produced unit is documented and can be analyzed.
  • 硅片
    wafer
    Savings
    ....
    The time it takes to:
    discover that a problem exists
    identify the root-cause of that problem
    find a solution and implement it
    Key questions to ask:
    what is the production capacity per hour?
    how large proportion of that capacity was affected?
    what is the difference in market value for the product?
    Savings depends on many variables unique to individual manufacturers
    A thorough investigation must be undertaken before credible assumptions and estimates can be made
  • Flow of information
    corporate
    management
    communication
    communication
    production management
    flow of material
    flow of material
    plant floor
  • Challenges without nerve system
    MS Excel
    reports
    Paper batch records
    • Production data is usually late
    生产数据滞后
    • Rarely current or reliably correct
    可靠性或精确度低
    Homemade MS Excel application for scheduling
    Data historian from vendor A
    corporate
    management
    Paper copies of SOPs
    Paper forms for data collection
    Local process control systems from different vendors and different technology eras
    • Voluminous and extremely difficult to assimilate
    海量数据使分析难度增加
    flow of material
    flow of material
    plant floor
  • Flow of information, comparison
    Corporate
    management
    Real-time prediction about future based on facts about the past, knowledge and experience
    Real-time running average available at all levels
    Production
    management
    Periodic average is insufficient and available too late
    Operational
    Year
    Week
    Day
    Second
    Quarter
    Month
    Present
    Future - Prediction
    Past- History
  • Solutions and services
    Machine
    integration
    设备自动化
    数据集成
    Analytical tools
    工艺分析方案
    Industrial IT
    tools
    工业制造方案
    Consulting
    services
    工艺分析优化
    顾问服务
    Spektron NIR
    先进分析仪器
  • Short about Prediktor
    • Consulting services and Industrial IT for optimization of manufacturing processes
    • 提供咨询服务和工业IT来优化生产工艺
    • Software engineers, process optimization experts and PV scientists cooperating
    • 团队成员:软件工程师、工艺优化专家以及光伏科学家
    • 8 years in the solar industry, high focus on R&D and innovation
    • 8年的太阳能行业经验,高度重视研发和创新
    • Cover the complete value chain from raw-material to complete PV module
    • 涵盖了从原料到组件的整条光伏价值链
    Dr. Steinar Saelid, CEO and Co-Founder of Prediktor
  • Selected Customers
  • Thank you!
    Prediktor is searching for partners:
    Solar PV manufacturers
    Universities and research institutes
    Machine suppliers
    Contact details:
    henrik.hassel@prediktor.cn
    Tel: +86 512 6818 7080
    Mobile:  +86 137 760 50422 
    中文: www.prediktorsolar.cn
    English: www.prediktor.no