Asset Utilization (OEE) Monitoring in Batch Process

Challenge

In order to raise efficiency and production standards, it is important to be able to analyze the performance of batch processes and identify time spent in each of the different process phases. Increased visibility into unproductive process time (for example during cleaning and maintenance and shift v shift differences in manual re-cleaning events) is necessary in order to enable users to take actions to reduce them. With the ability to increase production opportunities when reducing waiting times, overall profitability can also increase. 

Solution

Seeq offers users the ability to identify batch phases and sub-phases through process operating data analysis by combining step numbers, flow rates and valve modes. It also provides the ability to calculate metrics for each batch phase and create reports. This data provides operators with a better understanding of each batch phase and a long-term, big-picture view of where improvements can be made to save time and increase efficiency. Seeq can also integrate with historians for notifications and with PowerBI for management reporting. 

Benefits

Seeq allows for increased effectiveness in the overall analysis of batch process utilization, as well as improved documentation and cross-organization collaboration. It enables rapid identification of issues that arise during operations and replaces existing spreadsheets which can be complicated, inefficient, and make it difficult to collaborate.  

Data Sources

  • OSI PI and PI Asset Framework 

  • Maintenance Management System

Calculations and Capsules

With Seeq, capsules can identify different process phases as well as calculate key metrics for batch phases. Seeq users have access to continual contextualization of process data, which enables them to create accurate process signal statistics for each mode of operation. For example, operators can totalize flow rates only when in Cleaning vs Sterilization or identify max conductivity per cleaning event.

Summarizing Results

Seeq operators are able to more effectively analyze batch process utilization, eliminate existing shared excel documents to better streamline the process and improve both documentation and collaboration processes. The end result enables faster identification of operational problems so that they can be responded to and fixed sooner, reducing their impact to your bottom line.