Successfully reported this slideshow.
We use your LinkedIn profile and activity data to personalize ads and to show you more relevant ads. You can change your ad preferences anytime.

CWIN17 Toulouse / Industrial big data and mes, the winning combination to improve industrial performance n.praizelin-n.monnet-v2

506 views

Published on

Big Data applied to the industrial world is one of the main levers for value
creation.
Capgemini and Rio Tinto Aluminum have co-built and implemented an innovative methodology to develop and deploy predictive functions in plants. This methodology relies on the MES and provides predictive alerts to operators.
Open innovation accelerates this digital transformation.

  • Be the first to comment

  • Be the first to like this

CWIN17 Toulouse / Industrial big data and mes, the winning combination to improve industrial performance n.praizelin-n.monnet-v2

  1. 1. Industrial Big Data and MES, the winning combination to improve industrial performance Nicolas Monnet, Rio Tinto Nathalie Praizelin, Capgemini Toulouse, 28th September #CWIN17
  2. 2. September 28th 2017 │ Toulouse Copyright © 2017 Capgemini and Sogeti. All rights reserved. 2 #CWIN17 Rio Tinto, a global mining & metals company North America Africa Europe South America Australasia Asia We operate in 35 countries and employ 50,000 people. 4 product groups: • Iron Ore • Copper & Diamonds • Energy & Minerals • Aluminium
  3. 3. September 28th 2017 │ Toulouse Copyright © 2017 Capgemini and Sogeti. All rights reserved. 3 #CWIN17 The Rio Tinto Aluminium group Bauxite Alumina Aluminium • Our benchmark smelting technology: AP Technology™ • Aluminium Pechiney is the French subsidiary of Rio Tinto Aluminium (RTA). • The R&D teams of AP are the core of the RTA Technology and the facilities are located close to Grenoble (French Alps). 4 mines (35 Mt/year) 10 smelters (2.5 Mt/year)6 refineries (9 Mt/year)
  4. 4. September 28th 2017 │ Toulouse Copyright © 2017 Capgemini and Sogeti. All rights reserved. 4 #CWIN17 Electrolysis process 2 Al2 O3 + 3 C 4 Al + 3 CO2 Alumina: ~1 900 kg Carbon: ~ 400 kg Aluminium: ~1 000 kg CO2: ~ 1 300 kg
  5. 5. September 28th 2017 │ Toulouse Copyright © 2017 Capgemini and Sogeti. All rights reserved. 5 #CWIN17 Typical aluminium smelter Electrolysis 400 pots in line 400 000 Amps 400 000 tons aluminium/year Casthouse Freeze liquid aluminium in various products (ingots, slabs, billets, rod, etc.) Carbon Produce the carbon blocks (anodes) for the electrolysis pots Electrical Sub-station
  6. 6. September 28th 2017 │ Toulouse Copyright © 2017 Capgemini and Sogeti. All rights reserved. 6 #CWIN17 Our industry 4.0 vision for the Aluminium plants Data Analytics tools Process Optimization, Predictive Maintenance, Predictive Quality Generate alert Operation Center New sensors & massive data acquisition Process supervision Supply chain optimization Develop tools Excellence Center Advanced problem solving Data Analytics tools development Standardized IT & Automation (high business content) Process Control Manufacturing Execution System Advanced Operator Mobility & Wearable intelligence 3D vision & Augmented reality  Connect shop floor to centers UAV & UGV AGV & Automated Cranes
  7. 7. September 28th 2017 │ Toulouse Copyright © 2017 Capgemini and Sogeti. All rights reserved. 7 #CWIN17 Illustration with industrial Big Data DATA LAB Key equipment Main motors Electrolysis, Carbon, Casthouse Value added products Anode quality Process Optimization Predictive QualityPredictive Maintenance
  8. 8. September 28th 2017 │ Toulouse Copyright © 2017 Capgemini and Sogeti. All rights reserved. 8 #CWIN17 5. Subjects are priorized regarding their expected business value and accessibility 3. Business Experts, Digital & Data Specialist brainstorm and work together to bring out insights PoCs + Roadmap {Output} {Input} Data + Strategy .CODESIGN .SELECTION .COMBINATION .ENRICHMENT .PRIORIZATION.DISCOVERY.SYNCHRO .SHARE 1. Synchronization of stakeholders on the context, business challenges and AS-IS. 2. Presentation of technology innovations, uses cases and REX in several fields and sectors 4. Ideas and insights are challenged, reshaped and qualified (feasibility, workload, approach to validate the value…) Big Data roadmap definition phase
  9. 9. September 28th 2017 │ Toulouse Copyright © 2017 Capgemini and Sogeti. All rights reserved. 9 #CWIN17 How to address a use case
  10. 10. September 28th 2017 │ Toulouse Copyright © 2017 Capgemini and Sogeti. All rights reserved. 10 #CWIN17 Electrolysis process: the role of the carbon anodes
  11. 11. September 28th 2017 │ Toulouse Copyright © 2017 Capgemini and Sogeti. All rights reserved. 11 #CWIN17 Predictive detection of anode spikes Issue: periodic spikes crisis leading to production loss and carbon overcosts Objective: • Sustain productivity  Up to 1000$ per spike • Avoid crisis runaway  Avg 3% spikes  Crisis: 8%+ Work done: Generating a robust alert Balance between: • Detection: 50% • Anticipation: 8 days • Precision: 90% Anode data (new sensors) Hidden Markov Model Algorithm (HMM) alerts Results: Spikes(%)
  12. 12. September 28th 2017 │ Toulouse Copyright © 2017 Capgemini and Sogeti. All rights reserved. 12 #CWIN17 Annual Cash flow savings and Business Case Financial for Dunkirk smelter:  average cost of spikes crises: $2 500 000/year  potential savings with 8 day anticipation: $1 000 000/year Full potential savings for all Rio Tinto aluminium sites: Requires: • to package the algorithm in a “Predictive Function” • a platform to deploy this function on all plants in real-time operation. Dunkirk All sites Savings/year $1 000 000 $12 000 000 IRR 126% 112% NPV $5 000 000 $56 000 000
  13. 13. September 28th 2017 │ Toulouse Copyright © 2017 Capgemini and Sogeti. All rights reserved. 13 #CWIN17 Predictive functions in real time operation Plant Process Data Analytics (PPDA) • The PPDA module is the “container” for predictive functions • Data connectors with the production systems • Light embedded Hadoop infra for data preparation and predictive motor execution • Predictive alerts are displayed in operators electronic shift logs • Algorithm performance is continuously monitored Thanks to our standardized Manufacturing Execution System !
  14. 14. September 28th 2017 │ Toulouse Copyright © 2017 Capgemini and Sogeti. All rights reserved. 14 #CWIN17 How to accelerate 4.0 roadmap with Open Innovation Leveraging external funding and cooperative R&D • Reduce R&D costs • Accelerate “Time to Market” • Increase revenues via the development of disruptive solutions Open Innovation process Past 2 years? 4 European projects won 15 M€ of assets for only 3 M€ direct funding  A powerful lever effect ! X 5 Roadmaps: plants & strategy Challenges not covered Best external partners Best funding opportunity
  15. 15. September 28th 2017 │ Toulouse Copyright © 2017 Capgemini and Sogeti. All rights reserved. 15 #CWIN17 Horizon 2020 project: Monsoon European Commission funding program SPIRE Sustain Process Industry through Resource & Energy Efficiency Topic addressed: Plant-wide monitoring and control of data-intensive processes. • Build some Predictive Functions based on Big Data tools to optimize the production in process industries • Develop a plant operations platform to deploy these Predictive Functions in real-time Our consortium is made of 11 partners from 7 EU countries: ISMB, Rio Tinto (AP), Capgemini, ProBayes, Fraunhofer, GLN, CERTH, KIMW, TUK, AENOR, LCEN
  16. 16. September 28th 2017 │ Toulouse Copyright © 2017 Capgemini and Sogeti. All rights reserved. 16 #CWIN17 Main demo plant: Aluminium Dunkerque Aluminium Dunkerque is the highest-producing aluminium plant in the EU-28. One of the most modern smelters: 264 electrolytic pots operating at 380 kA, yearly producing 275 000 tons of aluminium, and consumes 3.7 TWh of electricity … equivalent to a 1-million people city consumption. Objective: Our first 4.0 plant !
  17. 17. September 28th 2017 │ Toulouse Copyright © 2017 Capgemini and Sogeti. All rights reserved. 17 #CWIN17 Conclusion Build a 4.0 vision with business cases Start with some high value creation use cases Find the good partners Accelerate with Open Innovation Have a dedicated demo plant
  18. 18. September 28th 2017 │ Toulouse Copyright © 2017 Capgemini and Sogeti. All rights reserved. 19 #CWIN17 Thank You! Nicolas Monnet Rio Tinto MESAL™ Product Manager nicolas.monnet@riotinto.com 725 rue Aristide Bergès – BP 7, Voreppe, 38340, France Insert contact picture Insert contact picture Nathalie Praizelin Capgemini MES and Digital Manufacturing Consultant Expert nathalie.praizelin@capgemini.com 95 chemin de l‘Etoile 38330 - Montbonnot Saint-Martin, France

×