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Challenges, Opportunities and Strategies for Integrating IIoT
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TEPCO Group and OSIsoft to Collaborate on IIoT
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Over the past several years, biopharmaceutical developer Shire has been working to implement a major overhaul of the way data is handled at their pilot plant in Lexington, Massachusetts. Before implementing the PI System, the company was generating, processing, and storing data in a complicated series of networks and standalone data islands and relying heavily on spreadsheets and manual data entry. One by one, Shire is integrating all of these diverse data sources into a single solution, the PI System. At the OSIsoft's 2016 Users Conference in San Francisco, Paul Turvey and Brad Ebel of Shire, presented how this project has streamlined the flow of information, improved user access to data, reduced errors, and had a substantial impact on the bottom line.
At OSIsoft's User Conference 2017 in San Francisco, Scrubgrass engineering manager Jeff Campbell told the story of how he used the PI System to: combine a variety of data streams into a powerful tool that plant operators can use to make real-time decisions; generate forecasts for optimizing the timing of planned equipment outages, one of which saved Scrubgrass $160,000 in a single week; and build a business case for saving the plant from shutdown.
Recently, Eli Lilly and Company (“Lilly”) launched an innovative pilot program to monitor the production of insulin pens, including assembly, injection molds and other equipment used to produce the pens. Production takes place at contract manufacturers (CMs) and Original Equipment Manufacturers (OEMs), and the OSIsoft PI System with PI Cloud Connect is being used to gather data to identify areas of improvement in the production process and machinery. As Brian Goldinger, Manufacturing IT Consultant at Eli Lilly, explained at the 2017 OSIsoft Users Conference in San Francisco, the real-time visibility enabled by the PI System will potentially allow Lilly to not only reduce manual data collection, the new process can elevate OEM/CM performance and allow the brand to scale production while maintaining its high standards of quality.
Sandoz, a subsidiary of Novartis that manufactures generic drugs, is subject to regular inspections from multiple regulatory agencies. In recent years, those agencies have begun focusing more on data integrity and audit trails for all digital records. In a presentation at OSIsoft's 2015 EMEA Users Conference in Prague, Alexander Haimayer, Head of Data Systems at Sandoz, described how OSIsoft's PI System helps the company stay in compliance with rigorous data archiving and manufacturing procedures required by the U.S. FDA - just one of the many agencies with jurisdiction over Sandoz's operations.
In 2011 when SECURE Energy Services bought the PI System™ for its liquids facilities, the company outlined a roadmap of future applications and target projects for the PI System. The roadmap included everything from creating management dashboards, to training, to process optimization. As part of its most recent roadmap project, SECURE began focusing on heavy equipment optimization in its Processing, Recovery and Disposal division through a pilot project at its landfills. The objective was to improve dozer operations and reduce the cost per ton to process waste.
Headquartered in Houston, Texas, Marathon Oil is a petroleum and natural gas exploration and production company that produces 438,000 barrels of oil per day. As commodities prices have fallen in recent years, it's more important than ever for this Fortune 500 company to optimize every asset and do more with less. Using the combination of the PI System and SAP HANA®, Marathon Oil: combined OT and IT data for a complete view of the organization, substantially reduced data preparation time and workload, quickly provided operators and engineers with critical insights, and optimized oil field production to increase profitability.