|
|
Advanced Process Management™
(APM™) ©2008
by Ultramax Corporation, If
you want to generate more value (as you define it) with your current
equipment, “OPTIMIZATION
is a matter of ATTITUDE and TECHNOLOGY” C. W. Moreno, Industrial Engineer Production
/ Manufacturing Operations The
basic situation and opportunities in industry are: ·
Operations of each production process are managed
through its Process Control System (PCS), including those with Advanced
Process Control (APC). A PCS
incorporates regulatory
process control (that maintains controlled variables close to
setpoints, the desired values), and sometimes supervisory control logic (that
automatically adjusts setpoints depending on conditions). This is part
of the infrastructure that enables production. ·
Plant personnel manage production / manufacturing
with the existing infrastructure -- to get more of what they want with more certainty
-- by tuning up the adjustments of: setpoints; biases (to
refine the adjustments made by the control logic); and sometimes manual
adjustments. These adjustment decisions
are sometimes made in response to changes in conditions or requirements, or
to learn how to do better. The objectives
usually include improving measured Key Performance Indicators (KPI, e.g. for safety, quality,
throughput, costs, and regulations). Optimal Performance Operations is to run production generating the best possible outcomes by applying the best operating
decisions: the adjustments; which is way above optimal regulatory control. The balance between
multiple objectives (metrics) is
resolved by: (a) constraints for capacity, availability, safety,
reliability and requirements; and (b) an overall (balanced) Performance Index
in direct economic impact, simpler quasi-economic approximations, or other surrogates
Optimal Performance Operations has the immediate benefit of making the achievement of
plant commitments easier (even as important uncontrolled conditions change
and when pushing the envelope), and long-term by enabling the company to
derive longer lasting profits from this production. Also, it sharpens the discovery of
barriers and opportunities. Optimization can be achieved with a
particular mind-set at the plant floor, maintained by upper management, and enabled
by optimization technology. Optimal Performance Operations Technology Ultramax® includes
multi-input and multi-output software that learns how to manage quantitatively
the set of all adjustments collectively to optimize production operations
performance according the set of all objectives and metrics selected by
the user. The
objectives may relate to downstream variables beyond the direct reach of single loop or multi-variable
regulatory control. The
optimum may be dynamic as conditions and requirements change. Ultramax hovers above the Process Control System under user
control, sensing and guiding production operations within prescribed limits
– sometimes discovering truly unexpected performance gains. It works best for repetitive normal operations,
usually excluding startups, change-overs, cleaning, maintenance, etc. As compared to other solutions which focus on improvements in equipment
and control systems (i.e., the infrastructure), Ultramax is
management-centered, an Industrial Engineering tool. It is a unique complement to
infrastructure improvements. For just optimization studies it is significantly
more effective than using Design of Experiments (DOE). For on-line dynamic optimization (for
changing conditions and business needs) it automates aspects of supervisory
control with great advantages over Neural Networks and First-principle
simulation models. Gains generated in a great variety of high-volume industries
usually range from a few $100K to a few $1M annually per process in tangible improvements;
and historically only 1% of processes are operating near optimally. Distinctions Operational Performance is measured by metrics that you define
based on data that you collect.
As necessary, Ultramax offers excellent options for you to create
common-sense, holistic metrics
so that calculated improvements are true bottom-line, avoiding hidden
undesirable effects. For example it can easily include the (increasing)
unit costs of energy, and metrics related to quality and consistency. Ultramax uses a proprietary Sequential Empirical Optimization (SEO) technology.
The SEO cycles of Adjust, Run & Get Data, Learn,
Advise makes fine re-adjustments every 10 min to two hours in continuous processes -- or every batch. It
performs self-learning optimization.
Starting from current adjustments, the periodic, modulated adjustments
extrapolate quickly and safely towards an optimum. SEO optimizes faster than other empirical
technologies because: (A)
It
learns immediately from the information in the collected operating
data – rather than waiting for the collection of a lot of data to be processed
later. (B)
It
can be started right away -- rather than waiting until the creation of
theoretical or empirical models, which is aggravated by the high costs in
manpower and/or in making experimental and validation runs with poor
performance. SEO is data driven
and useful when performance can be measured readily. All processes with which one can
exchange data (even manually) can be optimized as completely as the reproducibility
of the data. “If it can be measured, it can
be optimized.™” With Ultramax you
will be able to get profitability gains that are being wasted otherwise. On-line applications have interface or integration with the
PCS for automatic data exchange (OPC, uni- or bi-directional) to reduce work
and human errors. The plant can
select Advisory
optimization (where operators need to approve the re-adjustments), or Closed-Loop
optimization for further reduced drudgery after being satisfied with the
reliability of the application.
Closed-Loop reverts to Advisory if it detects abnormal or undesirable data, to inform operators right
away for awareness, and perhaps prevention for future increased reliability.
A unique feature applying Ultramax to manage production operations is:
it does not require changes to the process hardware or its
controls; it
is a “soft” solution; it leaves the infrastructure intact;
and you remain in full control. Using Ultramax will not delay any
improvement projects on your production assets, and now it is extremely
simple to re-start. If optimal operations
are not satisfactory for the business, then the process (equipment and/or
control system) needs to be improved.
That is, the non-intrusive Ultramax hovering above the process control
system enables you to determine that situation, but it will resolve only
those barriers that can be solved with better process adjustments. Summary of Unique Features of Ultramax The most distinguishing differences vs. alternate
solutions (from Automation, Control, and/or other Optimization suppliers) is: 1. Since the start of an optimization study or an on-line
implementation it both optimizes the fastest and safest. It also maximizes cumulative
performance. 2. It is the simplest optimization technology to implement
and maintain – e.g., its Suppliers only need to have general knowledge
about production operations, not especial process expertise. 3. It optimizes while engaging in regular operations: it
does not require performing non-productive, disruptive or expensive
experimental or validation runs. 4. It is Non-Intrusive – it does not require changes
to legacy process equipment or control system. 5. It performs full, non-linear, multivariable, balanced optimization
of all performance metrics, even of those affected but not controlled directly
by the PCS. 6. Because it is non-intrusive, generic and full-featured,
the software does not require customization, and thus training is
straight-forward and total costs are highy competitive. 7. For the same reasons, maintenance and reconfigurations for
changes in the optimization scope is fully in the hands of the user. However, as requested, we offer
on-site support such as training, guidance and reviews, plus remote support. 8. It can be applied in three optimization modes:
stand-alone advisory, integrated advisory (one and bi-directional interface),
and closed-loop; and users can readily change from one mode to the other
– users are always in full control. It can even be turned off so users can
continue with the old PCS but now with enhanced awareness and knowledge, as
happens with Studies. Process
Improvements and Optimization At any time, you may decide to fix problems or upgrade the equipment (the
infrastructure). If you require outside experts for
these improvements you will need a different kind of supplier than Ultramax Corporation, such as
suppliers of equipment, engineering, instrumentation, automation and controls
(as some Ultramax Agencies are). After any such changes, since Ultramax is a generic optimizer, it is
fully applicable to optimize the new operations. Even if the equipment already includes
some optimization tools, Ultramax is likely to still deliver more value
because of its ability to define and approach a holistic optimum – or
it could prove that operations are optimal as far as the data can tell. We propose
Ultramax as your company’s standard method to optimize and/or manage
production operations, at least for the bottleneck processes in KPI
achievement. Ultramax
Corporation and its Agencies welcome the opportunity to exchange insights and
to clarify any issues. Ultramax contributes
to best business practices. |
|
