Concept Note on PMIS

Background on Note: Competition is greater than ever before. To succeed,

manufacturers have to show a higher value proposition to market. Whether it’s through
faster response times, higher quality products, or exceptional customer service and
relationships, manufacturers are being asked to do more

This Concept notes focusing on leveraging existing IT applications (SAP, LIMS, DCS ) as well
as explore New Solutions like MES with Predictive analytics and IOT (Internet of things)
capabilities to drive a fundamental technological change in everyday Operation activities
resulting in Operation Excellence across all important Operations KPI’s of Plant.

The Overall purpose is to lay foundation stones of what is now being called as” Industry 4.0
“ . Industry 4.0 as the next phase in the digitization of the manufacturing sector, driven
emergence of analytics and business-intelligence capabilities; improvements in
transferring digital instructions to the physical world, 3-D printing and Internet of things.

Digitalisation is a long journet and based upon curent requirements following process are
covered as part of Digitalisation of Plant Operations
1. Digitalization of Production Log sheet and its seamless integration with SAP, lims
and DCS system
2. Batch process analysis and SPC/
SQC; Mass Balance and Golden Batch Reports from
existing DCS/LIMS/SAP system.
3. KPI Based dashboard with SAP Hana /Business Objects platform
4. Alarm Management System
5. Analytics to support predictive maintenance and more-robust
process management

Business Case for Log sheet Digitalization

I. As Is Situation / Challenges at PI

 Operation across PN01 plants except MPP4A are carried out manually; No PLC/DCS
for controlling process operations
 Business operations of these plants are managed through SAP and all the data entry
into SAP is manual.
 Production operations for products are monitored and supported by log sheet /SOP.
 QA controlled versions for Logbook/SOP/WI ;
 All data required for log sheet entered manually; then into excel and finally into
 SAP. In SAP too only limited amount of data is being entered leading to limited use
for Norms and costing calculation.
 Even in case of DCS Based plants Production data is analyzed with the
help of production reports in various formats generated manually.
 Manual preparation of consolidated quality report.
  Considerable man-hours are utilized in analyzing production data/Quality data
and entering the same into SAP. No readily available Trend Analysis for
Production reports on golden batch parameters.
 Lack of visibility of shop floor operations at various levels.
 DRM /QMS Reports are made manually

II. Key Deliverables of Solution Proposed

‘ Log sheet Digitalization across all Plants


Performance Dashboard for Supervisor and Plant Manager

Golden Batch Analysis

Plant Alarm Information Management System.

 Log sheet Digitalization in All Plants

Digitization of documented Operator Instructions; Provide entry screens for
identified key Log sheet parameters; Record operation related information into
Logbook; Shift Handover timing and information management, Work Instruction
Tracking; Visibility into Operations: Easy access to all shift logs, instructions,
checklists and events; Auto booking/transfers of materials/utilities into SAP and
facilitate the same; Down Time Capturing; Quality Results Capturing & Workflow
 Production Supervisor Dashboard
Dashboard to monitors and visualizes KPIs, inventory and process data by
effectively collating key production and quality information ; Linking with o
information such as historic process and event data provides a valuable insight into
diagnosing production problems

 Golden Batch Analysis/SPC

Based on SPC/SQC Analysis defines and identifies Golden Batch parameters
Analyses cycle time variance and quality as batch Key Performance Indicators to
identify problems in the production processes, allowing improvements to be made.
 Benefits

 Easy business-wide information distribution

 Reduces triplicate data entry by production supervisors in Manual plants.
 Single point of entry to access all information
 Plant data is enhanced and used throughout the business
 Provision of long term plant history
 Event-triggered processing of data into business information
 Time-resolved event history
 Facilitating timely and effective decision making, the promotion of proactive
problem solving, and possible root cause identification.
 Knowledge repository for plant operations for proactive and consistent actions
 Minimizing errors related to manual entry. Batch preparation data will be
captured directly from shop floor.
SYSTEM LAYOUT – PLANT ALARM MANAGEMEN T SYSTEM (JAMBUSAR SITE)

Analysis and Reports:

All Reports is configurable and configuration option like generation of report at
specified time, filters, mailing option and printing option is available.

Frequency Analysis – Frequency analysis is configurable for various options like filter on
various fields of alarms, order of information displayed and no. of columns to be showed
in report.

Summary Report – Summary report is available in graphical representation of overall

system to show how many alarms of which category occurred during selected
filtering option like duration or area or Tag name.

Duration Analysis – Duration Analysis shows the time, average, max and minimum
time between alarms generated for each Tag name.
 IV. Current Progress:

1. MPP6 (OC) Plant Digital log sheet generation work completed.

2. MPP7 (PCM) Plant Digital log sheet generation work completed. Under review.
3. MPP4A (OC) Plant Digital Log sheet generation work is under progress.
4. Plant Alarm Information Management system finalized. Implementation under
progress.

IT is working on Digitalization of Log sheet for Manual Plant (MPP3) plant to showcase the
capabilities;

V. Way Forward:

 Demo to Team Members and Operation team on go ahead for Manual

Log sheets digitalization
 Capex Investment approval; detail capital expenditure to be worked about.
 Time for Implementation: 3 to 6 months initially for each Plant.
 Resource Requirement: Good amount of Participation from Operation and PD is
required for input on parameters related to Dashboard and Golden Batch.
 Phase wise Implementation Approach
o Phase 1 : Log sheet Digitalization and its integration with SAP for auto
Postings
o Phase II: Dash Board development for plant performance monitoring at
different level.
 : Plant Alarm Information Management system at Jambusar site.
(MPP6 Plant)
o Phase III: Golden Batch Data Analysis through DCS /SAP.