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

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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

    1. 1. Agenda<br />Process visibility and <br />PV value chain optimization<br />27. May 2010<br />Henrik Hassel<br />Managing Director, <br />Prediktor China<br />
    2. 2. 多晶硅材料<br />silicon<br />硅片<br />wafer<br />硅锭<br />ingot<br />电池<br />cell<br />组件<br />module<br />PV 电厂<br />Power plant<br />Solar PV production chain<br /><ul><li>Reduce costs
    3. 3. Improve quality
    4. 4. Increase throughput</li></ul>Goal: more solar energy at continuously lower costs!<br />
    5. 5. 硅片<br />wafer<br />Sample case, wafer production<br />High proportion of <br />wafers with unacceptable<br />resistivity levels<br />....<br /><ul><li> What do these wafers have in common?
    6. 6. What is the root-cause behind this?
    7. 7. How can we find out as fast as possible?
    8. 8. What corrective actions do we need to take?
    9. 9. All wafers come from bricks produced in line #3, furnace #2
    10. 10. This furnace has high deviation in energy consumption
    11. 11. Production is stopped, maintenance checks furnace #2
    12. 12. Gas leakage identified and fixed
    13. 13. Problem solved, production resumes as normal</li></ul>#2<br />
    14. 14. Brick position of defect wafer<br />The entire production history<br />of each produced unit is documented and can be analyzed.<br />
    15. 15. 硅片<br />wafer<br />Savings<br />....<br />The time it takes to:<br />discover that a problem exists<br />identify the root-cause of that problem<br />find a solution and implement it<br />Key questions to ask:<br />what is the production capacity per hour?<br />how large proportion of that capacity was affected?<br />what is the difference in market value for the product?<br />Savings depends on many variables unique to individual manufacturers<br />A thorough investigation must be undertaken before credible assumptions and estimates can be made<br />
    16. 16. Flow of information<br />corporate<br />management<br />communication<br />communication<br />production management<br />flow of material<br />flow of material<br />plant floor<br />
    17. 17. Challenges without nerve system<br />MS Excel<br />reports<br />Paper batch records<br /><ul><li>Production data is usually late</li></ul>生产数据滞后<br /><ul><li>Rarely current or reliably correct</li></ul>可靠性或精确度低 <br />Homemade MS Excel application for scheduling<br />Data historian from vendor A<br />corporate<br />management<br />Paper copies of SOPs<br />Paper forms for data collection<br />Local process control systems from different vendors and different technology eras<br /><ul><li>Voluminous and extremely difficult to assimilate</li></ul>海量数据使分析难度增加<br />flow of material<br />flow of material<br />plant floor<br />
    18. 18. Flow of information, comparison<br />Corporate<br />management<br />Real-time prediction about future based on facts about the past, knowledge and experience<br />Real-time running average available at all levels<br />Production<br />management<br />Periodic average is insufficient and available too late<br />Operational<br />Year<br />Week<br />Day<br />Second<br />Quarter<br />Month<br />Present<br />Future - Prediction<br />Past- History<br />
    19. 19. Solutions and services<br />Machine <br />integration<br />设备自动化<br />数据集成<br />Analytical tools<br />工艺分析方案<br />Industrial IT<br />tools<br />工业制造方案<br />Consulting<br />services<br />工艺分析优化<br />顾问服务<br />Spektron NIR<br />先进分析仪器<br />
    20. 20. Short about Prediktor<br /><ul><li>Consulting services and Industrial IT for optimization of manufacturing processes
    21. 21. 提供咨询服务和工业IT来优化生产工艺
    22. 22. Software engineers, process optimization experts and PV scientists cooperating
    23. 23. 团队成员:软件工程师、工艺优化专家以及光伏科学家
    24. 24. 8 years in the solar industry, high focus on R&D and innovation
    25. 25. 8年的太阳能行业经验,高度重视研发和创新
    26. 26. Cover the complete value chain from raw-material to complete PV module
    27. 27. 涵盖了从原料到组件的整条光伏价值链</li></ul>Dr. Steinar Saelid, CEO and Co-Founder of Prediktor<br />
    28. 28. Selected Customers<br />
    29. 29. Thank you! <br />Prediktor is searching for partners:<br />Solar PV manufacturers<br />Universities and research institutes<br />Machine suppliers<br />Contact details:<br />henrik.hassel@prediktor.cn<br />Tel: +86 512 6818 7080<br />Mobile:  +86 137 760 50422 <br />中文: www.prediktorsolar.cn<br />English: www.prediktor.no<br />

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