PI at

PI at PI at

More than just dessert!

About Eastman…

Headquarters: Kingsport, TNManufactures and Markets

Plastics, Chemicals & Fibers

About 15,000 employees

30 countries

2000 sales: $5.3 billion.

ArgentinaArgentinaPETPET

Moundsville, ALMoundsville, AL

Philadelphia, PAPhiladelphia, PA

Uruapan, MexicoUruapan, Mexico

Rexdale, Ontario, CanadaRexdale, Ontario, Canada

Pleasant Prairie, WIPleasant Prairie, WI

Newark, NJNewark, NJ

LaVergne, TNLaVergne, TN

Columbus, GAColumbus, GA

Forest Park,, GAForest Park,, GA

Ennis, TXEnnis, TX

Lynwood, CALynwood, CA

Portland, ORPortland, OR

South Holland, ILSouth Holland, IL

Carpentersville, ILCarpentersville, IL

Toronto,Toronto,CanadaCanadaPETPET

Jefferson, PAJefferson, PA

Franklin, VAFranklin, VA

Columbia, SCColumbia, SCPETPET

Kingsport, TNKingsport, TNhundreds of chemicals,hundreds of chemicals,fibers & plasticsfibers & plastics

Batesville, ARBatesville, ARspecialty organicspecialty organicchemicalschemicals

Longview, TXLongview, TXover 40 chemicalsover 40 chemicals& plastics& plastics

Roebuck, SCRoebuck, SCtextile chemicalstextile chemicals

Savannah, GASavannah, GA

Veracruz, MexicoVeracruz, MexicoPETPET

Sokolov, Czech RepublicSokolov, Czech Republictextile chemicalstextile chemicals

Waterford,Waterford,IrelandIreland

Kallo, BelguimKallo, Belguim

Bury, UKBury, UK

Sant’ Albano, ItalySant’ Albano, Italy

Cola’ Di Lazise, ItalyCola’ Di Lazise, Italy

Molndal, SweedenMolndal, Sweeden

Middelburg, NetherlandsMiddelburg, Netherlands

Rotterdam, NetherlandsRotterdam, NetherlandsPTA & PETPTA & PET

Stonehouse, UKStonehouse, UK

Hamburg, GermanyHamburg, Germanyspecialty polymersspecialty polymers

Dusseldorf, Ger.Dusseldorf, Ger.specialty polymersspecialty polymers

WalesWalesfine chemicalsfine chemicals

SpainSpainPET & CHDMPET & CHDM

Kuantan, MalaysiaKuantan, MalaysiaEastar & SpectarEastar & Spectar

Jurong Town, SingaporeJurong Town, Singapore

Nan Ping, ChinaNan Ping, China

Tanggu, ChinaTanggu, China

Hong KongHong Kongpharmaceuticalpharmaceuticalintermediatesintermediates

SingaporeSingaporeOXO chemicalsOXO chemicals

Nanjing, ChinaNanjing, ChinaeasTotac hydrocarboneasTotac hydrocarbontackifying resintackifying resin(to be completed late (to be completed late 2000)2000)

WorkingtonWorkington

HartlepoolHartlepool

Manufacturing Sites

Presenters

Johnette McDanielPrincipal Systems AnalystLongview, TexasLeader - PS-RLINK Worldwide

Bill WightSystems AssociateKingsport, TennesseeProject ArchitectProcess Excellence Team

History of PI at Eastman

‘90- 40,000 tags - Utilities Control System‘93- Manufacturing Process Improvement

- Utilities Expands Functionality‘94- Manufacturing Links to AI Tools (EPC)

- Interface PI to Internal MES’s‘95- Full Information System (Different Archive)‘97- Began MESA Project (1.6M tags)‘99- Two Latin American Plants in Operation‘01- North American Startup

Manufacturing Enterprise Systems Alignment

What’s a “ ”?What’s a “ ”?

Manufacturing Enterprise Systems Alignment

ArchitectureArchitecture

ProductArchitecture

Common User View

R/3

Planning

Schedule

Initiate Production

Runs

Production Records

Inventory Management

Ship

EIW

Process/ Product

Knowledge

Mgmt. Summary

Bus. Intel.

Decision Support

PIMS

Process Control

Process Conditions

Lab Inst.

LIMS

Functional Architecture

Process Data Collection

Data ArchivingTrend DisplaysExcel InterfacePerf.

Equations

Mgmt. Reporting

Oper. Reporting

Measures“Roll-up”MIS Data

Feeds

Sample Mgmt.Instrument

InterfacingSPC Data FeedCalibrationStandardsMethods

Inventory TrackingPlanning/

SchedulingBatch RecordsQuality Release

Process RecipesProcess

InstructionsCert. Of AnalysisShipping

SPCStd. DisplaysLab Data

AccessCalc.

ProductionCalc. Usage

ProcessProcess

DataData

SAP R/3

TrackTrack

MaterialsMaterials Purchased LIMS

Scales, PCS

Physical Architecture - I

PIMS

Materials (R/3)

RecordRecord

AnalysesAnalyses

ApplyApply

StatisticsStatistics

DataData

AnalysisAnalysis

Information

Physical Architecture - II

RS/6000AIX

Oracle

RS/6000AIX

Oracle

DELLNT ServerSQLServer

DELLNT ServerSQLServer

TCP/IPPS-RLINK

SM-IDI

TCP/IPPS-RLINK

SM-IDI

PI Products

•Archive

•Field Device Interfaces

•ProcessBook

•DataLink

•AlarmView

•Manual Logger (incl. HHT)

•BatchView

•SQC add-in

Team “Products”

• Process Changes

•Datasheets

•SampleMonitor

•SPC Alarm Client

•Required Data Monitor

• LIMS Interface

•Statistical Analysis Facility

Manufacturing Manufacturing Business ProcessesBusiness Processes

• Receive Raw Materials

• Prepare to Produce Monitor Manufacturing

• Qualify Product

• Post Production / Usage

• Management Information

Monitor Manufacturing

PreparePrepare

Process Changes UtilityProcess Changes Utility

To LIMS:• Product ID• Batch No.• Process State

To LIMS:• Product ID• Batch No.• Process State

To PI:• State Tags• SPC Limits• Other Tag Settings

To PI:• State Tags• SPC Limits• Other Tag Settings

Monitor ManufacturingMonitor Manufacturing

Establish Process Conditions

Collect & CompareCollect & Compare

Data from multiple Instruments (Honeywell DCS, Fisher DCS, Fisher DeltaV DCS, Intellution Fix PC control)

OFF GAS PRESS RBL 30 STM DA-404 KLB/HR Blr12 Boiler Feed Water FlD-350 Bin Weight

1/6/00 7:54:33 AM 1/6/00 3:54:33 PM8.00 Hour(s)

54ADC:PI04B-57.PV

74DC:FC8E7.OP

52PI:FI-08-191/AI1.PV

WI350.PV

50

100

150

200

0

24077.03906

59.8

164.512

0.12

54ADC:PI04B-57.PV

74DC:FC8E7.OP

52PI:FI-08-191/AI1.PV

WI350.PV

Monitor ManufacturingMonitor Manufacturing

Data About the Health of the Process

To Expected Results

Archive, Trends, HHT, Analyticals

Archive, Trends, HHT, Analyticals

SampleMonitorSampleMonitor

DataSheetsDataSheets

SQC Add-inSQC Add-in

Alert & RespondAlert & RespondOperator to Deviations

Capture ResponseFor Later Analysis

Monitor ManufacturingMonitor Manufacturing

PIAlarmViewPIAlarmView

MESA Alarm ClientMESA Alarm Client

Select and RecordCauses & Actions

Select and RecordCauses & Actions

Manufacturing Manufacturing Business ProcessesBusiness Processes

• Receive Raw Materials

• Prepare to Produce

• Monitor Manufacturing

• Qualify Product Post Production / Usage

• Management Information

Post Production / Usage

Standard FeaturesStandard Features

• Start/Stop Control Recipes & Phases

• Processbook

•Automated via Excel

• Post actual Production, Consumption & Activity quantities

•Backflush Consumption Quantities (Unrestricted and Restricted)

•Varying Levels of Automation

PI-PCS Interface

User selectsUser selects

Default current time.

(User can change)

Default current time.

(User can change)

Calculated from LBS

Calculated from LBS

Calculated from flow rate PI tag.

User can change.

Calculated from flow rate PI tag.

User can change.

User selectsUser selects

Default from PI tags.

Default from PI tags.

DefaultDefault

Default from PI tags.

Default from PI tags.

Post Post Production

Unsolicited MessagesUnsolicited Messages

•Material Transfers

•Batch Creation (PI_BT_CR)

•Batch Characteristics

(PI_BT_CL)

PI to SAP

CustomizationsCustomizations

•SAP to PI-Tag Value Updates• Quality Test Results from SAP to PI

• System Management and Alarming

•Eastman Wrappers• Recipe Management

• Post Production/Usage/Activities

•Automated Tools

Bulk ConfigurationBulk Configuration

Digital TagsDigital Tags

PS-RLINK TagsPS-RLINK Tags

TestingTesting

Configure Configure Automated Configuration Tools

ManageManageAutomated User Tools

Control Recipe Stop/StartControl Recipe Stop/Start

ConfirmationConfirmation

Materials Maintenance

Materials Maintenance

Monitor Monitor Interface Monitoring

& Intervention

I/T Support AlarmsI/T Support Alarms

User AlarmsUser Alarms

Debugging ToolsDebugging Tools

PS-RLINK Statistics

•6 Manufacturing Divisions

•89 Resources (Reporting Locations)

•>800 Materials

•>12,000 MT Reported Daily

•Minimal Problems

Of course, there’s still…Of course, there’s still…

Manufacturing Manufacturing Business ProcessesBusiness Processes

• Receive Raw Materials

• Prepare to Produce

• Monitor Manufacturing

• Qualify Product

• Post Production / Usage Management

Information

Tools for Power Users

PI DataLink:Ad Hoc Query / End-User Dev.

PI DataLink:Ad Hoc Query / End-User Dev.

Stat. Analysis Facility:Quality System

MaintenanceChart Delivery

Stat. Analysis Facility:Quality System

MaintenanceChart Delivery

ProcessBook:Process Data vs.Analytical Data

ProcessBook:Process Data vs.Analytical Data

Required Data Monitor…ensuring that critical data is archived

ConfigureConfigure

MonitorMonitor

Cognos PowerPlay & Impromptu

ArgentinaArgentinaPETPET

Moundsville, ALMoundsville, AL

Philadelphia, PAPhiladelphia, PA

Uruapan, MexicoUruapan, Mexico

Rexdale, Ontario, CanadaRexdale, Ontario, Canada

Pleasant Prairie, WIPleasant Prairie, WI

Newark, NJNewark, NJ

LaVergne, TNLaVergne, TN

Columbus, GAColumbus, GA

Forest Park,, GAForest Park,, GA

Ennis, TXEnnis, TX

Lynwood, CALynwood, CA

Portland, ORPortland, OR

South Holland, ILSouth Holland, IL

Carpentersville, ILCarpentersville, IL

Toronto,Toronto,CanadaCanadaPETPET

Jefferson, PAJefferson, PA

Franklin, VAFranklin, VA

Columbia, SCColumbia, SCPETPET

Kingsport, TNKingsport, TNhundreds of chemicals,hundreds of chemicals,fibers & plasticsfibers & plastics

Batesville, ARBatesville, ARspecialty organicspecialty organicchemicalschemicals

Longview, TXLongview, TXover 40 chemicalsover 40 chemicals& plastics& plastics

Roebuck, SCRoebuck, SCtextile chemicalstextile chemicals

Savannah, GASavannah, GA

Veracruz, MexicoVeracruz, MexicoPETPET

Sokolov, Czech RepublicSokolov, Czech Republictextile chemicalstextile chemicals

Waterford,Waterford,IrelandIreland

Kallo, BelguimKallo, Belguim

Bury, UKBury, UK

Sant’ Albano, ItalySant’ Albano, Italy

Cola’ Di Lazise, ItalyCola’ Di Lazise, Italy

Molndal, SweedenMolndal, Sweeden

Middelburg, NetherlandsMiddelburg, Netherlands

Rotterdam, NetherlandsRotterdam, NetherlandsPTA & PETPTA & PET

Stonehouse, UKStonehouse, UK

Hamburg, GermanyHamburg, Germanyspecialty polymersspecialty polymers

Dusseldorf, Ger.Dusseldorf, Ger.specialty polymersspecialty polymers

WalesWalesfine chemicalsfine chemicals

SpainSpainPET & CHDMPET & CHDM

Kuantan, MalaysiaKuantan, MalaysiaEastar & SpectarEastar & Spectar

Jurong Town, SingaporeJurong Town, Singapore

Nan Ping, ChinaNan Ping, China

Tanggu, ChinaTanggu, China

Hong KongHong Kongpharmaceuticalpharmaceuticalintermediatesintermediates

SingaporeSingaporeOXO chemicalsOXO chemicals

Nanjing, ChinaNanjing, ChinaeasTotac hydrocarboneasTotac hydrocarbontackifying resintackifying resin(to be completed late (to be completed late 2000)2000)

WorkingtonWorkington

HartlepoolHartlepool

Manufacturing Sites

Questions?Questions?