Recommended
Recommended
More Related Content
What's hot
What's hot (20)
Similar to Asia NOC Bridges Business-wide Performance Objectives and KPIs through an Advanced Analytics System
Similar to Asia NOC Bridges Business-wide Performance Objectives and KPIs through an Advanced Analytics System (20)
More from Yokogawa1
More from Yokogawa1 (20)
Recently uploaded
Recently uploaded (20)
Asia NOC Bridges Business-wide Performance Objectives and KPIs through an Advanced Analytics System
- 1. Yasunori Kobayashi General Manager, MES Solution Development Expert Yokogawa November 12, 2020 Asia NOC bridges business-wide performance objectives and KPIs through advanced analytics system
- 2. Agenda 1. Challenges in Business Performance Management 2. Business-wide, Bridged KPI Structure 3. Industrial KPI Templates 4. Real-time KPI Digitalization 5. Real-time KPI Dashboarding 6. KPI Analytics and Online Prediction using AI ML 7. Profit Improvement Consulting 8. Typical Quick-win Benefits 9. Use Case -PTT GSP
- 3. Challenges in Business Performance Management
- 4. Business Performance Management Challenges ■ KPI Disconnect – between C-level and Operators ■ Partial KPI Optimization – due to silos ■ Invisible KPI Trade-off – stability vs profitability ■ Ex-post Action – due to monthly review ■ Excess Safety Margin – on the plant floor How can these challenges be addressed using Industrial Best Practice and Disruptive Digital Technologies? Think Yokogawa “Profit-driven Operation”
- 5. Good Strategy vs Bad Strategy ■ Good strategy involves coherence between front line and top management ■ Critical to connect and cascade up/down performance objectives and real-time measurement ■ KPI structures must be: ◆ Dynamic / real-time ◆ Bridged (vertical) ◆ Business-wide Tier 1 Top Managers Tier 2 Business Unit Tier 3 Front-Line
- 7. Level / User KPI Usage Finance KPI Operations KPI HSSE KPI Business/ C-level Monthly review Analysis Prediction Gross profit, EBITDA Sales volume, Realized gross margin OPEX, ROACE, CAPEX Maintenance cost index Unit cash cost Plant utilization , Shutdown & slowdown Throughput/Production volume Operational availability, Mechanical availability Energy intensity index, Gross margin asset performance Feedstock supply & offtake Major fire, Explosion, Major spill Lost time injury frequency Greenhouse gas emission Loss of primary containment Fire security incident Management/ Staff Real-time Control (manual/auto) Analysis Prediction Production KPI Profit KPI Energy KPI RAM KPI HSSE KPI Plant utilization Feed plan % Products plan % Raw/Additional material High value product yield Plant material loss Energy consumption Net heat absorbed Heat recovered Asset availability Asset maintenance cost Same as upper KPIs Technical/ Engineers Unit utilization max% Each product yield Each material loss Chemical consumption Fuel consumption Steam consumption Electricity consumption Heat absorbed Quality giveaway Furnace allowance Quench water PH Compressor turbine allowance Compressor surge allowance Column flooding % TLE Uo/Duty, Dryer delta-P Operational conditions causing major fire or explosion Critical Operation Parameter (COP) causing plant shutdown Emission Operation/ Operators Related process variables Related process variables Related process variables Related process variables Related process variables Business-wide Bridged Give Workforce a chance to drill down and optimize performance in their level Business-wide, Bridged KPI Structures (Patent pending)
- 8. Upstream ■ Gas processing/separation ■ LNG liquefaction/regasification ■ Oil field Downstream ■ Condensate refining ■ Oil refining ■ Ethylene ■ Aromatics Terminal ■ Tank terminal Chemical ■ Ammonia ■ Ammonium nitrate ■ Ethylene oxide ■ Ethylene glycol ■ Ethanol amine ■ Elastomer ■ Fiber spinning ■ MMA ■ Polyethylene ■ Polypropylene ■ Polycarbonate ■ PTA ■ PVC ■ SBR ■ VCM Power ■ Coal fired ■ Combined cycle SPI Objective Production SPI Profit SPI Energy SPI Reliability SPI Safety SPI Example of Ethylene 250KPIs Others ■ Oleo ■ Gold mining ■ Sewage disposal Help PDO user to achieve early ROI by shortening engineering period Industrial KPI Templates (Yokogawa IP)
- 9. Real-time KPI Digitalization (Patent pending) Data Adaptors Data Integration Real-time KPI Digitalization & Dashboarding VnetI/P OPC UA OLE DB B2MML SOAP REST Excel Services Specific Add-inns Planning, Scheduling Production Management Accounting, etc. KPI Template & Builder Procedural Automation Dashboard Template & Builder Guidance Static Simulator KPI Limit & Alarm Statistical Analysis Export Multi-variables Analysis Reporting AI Machine Learning Benchmarking Regression Model Online Prediction AI Model Software Sensor Static Simulator Autonomous KPI Control Data Analytics & Reporting Online Prediction Cloud & On-premise Available
- 10. Real-time KPI Dashboarding (Patent pending) Actionable Dashboards based on Industrial Knowledge Karaoke Dashboard visualizing KPI Trade-off Tree Dashboard indicating cause of KPI problem
- 11. Real-time KPI Dashboarding (Patent pending) Actionable Dashboards based on Industrial Knowledge Trend Dashboard conducting agile & right action AI Procedural Automation automating cause identification & measure
- 12. KPI Analytics and Online Prediction using AI ML Data Adaptors Data Integration Real-time KPI Digitalization & Visualization VnetI/P OPC UA OLE DB B2MML SOAP REST Excel Services Specific Add-inns Planning, Scheduling Production Management Accounting, etc. KPI Template & Builder Procedural Automation Dashboard Template & Builder Guidance Static Simulator KPI Limit & Alarm Statistical Analysis Export Multi-variables Analysis Reporting AI Machine Learning Benchmarking Regression Model Online Prediction AI Model Software Sensor Static Simulator Autonomous KPI Control Data Analytics & Reporting Online Prediction Cloud & On-premise Available
- 13. Profit Improvement Consulting Examples of Implemented Solution Control • Adjustment of performance trade-off • New target setting • Control parameter tuning • APC model update • LP vector update • Control design modification Plant/Process • Capacity expansion • HX rearrangement • Catalyst replacement Operational Strategy • Load shift between compressors • Cleaning timing optimization Business/Human Resource • Work process modification • Product lineup change • Workforce capability enhancement DEFINE/DISCOVER 1-2 months DEVELOP 3-6 months DELIVER 6 months + SUSTAIN 6 months + ▪ Senior management alignment ▪ Data collection & staff interviews ▪ Assessment of current situation, initiatives & CAPEX plans ▪ Identification of opportunities and benefits ▪ Benchmarking and gap analysis ▪ Solicit initial stakeholder ‘buy-in’ Activities ▪ Quick-win opportunities for rapid implementation ▪ Initial set of opportunities and estimated benefits ▪ Performance gaps and focus area priorities ▪ Roadmap for ‘Develop’ phase Deliverables ▪ Mid management alignment ▪ Integrated road map for ‘Deliver’ phase ▪ Individual opportunity delivery plans and resource requirements ▪ Organizational changes/work process upgrades to support delivery of benefits and continuous improvement ▪ Quick-win benefits capture ▪ Prioritized opportunity list with potential benefits and KPIs ▪ Detailed implementation plan ▪ Organizational design/work process documents ▪ Delivery via KBC on-site support ▪ Performance changes inclusions in business forecast ▪ KPI implementation for benefits ▪ Implementation of org. changes and job performance profiles ▪ Modification of work processes ▪ Update of tools and applications ▪ Preparation for ‘Sustain’ Phase ▪ Program benefit tracking tool and template ▪ Financial and operational benefits ▪ PI tree for performance monitoring and target setting ▪ Re-structured organization ▪ Manual of work processes ▪ Training materials ▪ Continuous improvement tool-kit ▪ Quarterly performance challenge by visiting specialists ▪ Tuning of organizational structure and work processes based on tam feedback ▪ Maintenance/upgrade of tools and applications ▪ Remote technical support and hotline ▪ Financial and operational benefits ▪ Quarterly program ‘health check’ ▪ Tool-kit upgrades
- 15. Typical Quick-win Benefits: 1-3% of energy saving Low High Capacity Energy Cost Savings M$ / yFuel Price (LNG Price) Low case is US price and high case is Japan price, respectively. Prices are based on the trend from 2017 to 2019. $/GJ 3.0 11.0 unit Energy Cosumption GJ / ton Low case (3.0 $ / GJ) High case (11.0 $ / GJ)$/ton 153.60 563.20 Coal Price High and low price of coal produced in Australia and South Africa from 2017 to 2019 1% reduction 3% reduction 1% reduction 3% reduction$/GJ 1.93 4.62 $/ton 50.00 120.00 Refinery 230 kbbl/d 3.0 1.24 3.71 4.53 13.60 Ethylene (Naptha feed) 500,000 ton/y 19.0 0.29 0.86 1.05 3.14 Ethylene (Ethane feed) 500,000 ton/y 12.2 0.18 0.55 0.67 2.01 LDPE 500,000 ton/y 7.5 0.07 0.20 0.25 0.74 PP (Vapor phase process) 300,000 ton/y 6.0 0.05 0.16 0.20 0.59 Paraxylene 300,000 ton/y 10.3 0.09 0.28 0.34 1.02 Ethylene Glycol 300,000 ton/y 5.9 0.05 0.16 0.19 0.58 Stylene Monomer 300,000 ton/y 9.8 0.09 0.26 0.32 0.97 VCM 500,000 ton/y 4.1 0.06 0.18 0.23 0.68 Ammonia 500,000 ton/y 6.2 0.09 0.28 0.34 1.02 Urea 500,000 ton/y 3.7 0.06 0.17 0.20 0.61 LNG Combined Cycle Power Plant 500 MW 0.63 GJ/MWh 0.08 0.25 0.30 0.91 Coal Fired Power Plant 1,000 MW 1.42 GJ/MWh 0.24 0.72 0.57 1.72 LNG Production 5,000 kton/y 4.0 GJ/t 0.60 1.80 2.20 6.60 Oil Field 1,000 kbbl/d 51.1 GJ/kbbl 0.56 1.68
- 16. Use Case PTT Gas Separation Plant
- 17. PTT Gas Separation Plant, Thailand ■ Yokogawa KPI template helped PTT to achieve early ROI ■ Production Division is happy to use PDO because PDO helps Operators to understand how their KPIs impact Management KPIs, and helps to realize more profitable operation with less support from Technical Division ■ Yokogawa SME discovered approx. USD5M improvements analyzing SPI historian (quick-win opportunity was USD500K)
- 18. Profit-driven Operation Suite Business KPI Dashboard Operation KPI Dashboard Integrated KPI Design Procedural Automation for KPI Control Advanced Operation Graphic Online Prediction Data Analytics VR PDO Training Profit Improvement Program Team Effectivenes s CCR Desig n Permit to Work Work Instruction Shift Handover Alarm Mngm t Operation Improvemen t ■ Help the right person to make a right decision at the right time for achieving profit-driven operation through the plant lifecycle
- 19. The names of corporations, organizations, products and logos herein are either registered trademarks or trademarks of Yokogawa Electric Corporation and their respective holders. Any questions?