Dow Chemical Eliminates Raw Material Management Errors with aspenONE MES Suite
公司规模
1,000+
地区
- America
国家
- United States
产品
- aspenONE MES Suite
- Aspen InfoPlus.21
- Aspen Production Execution Manager
技术栈
- MES solution
- Warehouse data management system
- Mobile human machine interface (HMI)
实施规模
- Enterprise-wide Deployment
影响指标
- Productivity Improvements
- Waste Reduction
技术
- 功能应用 - 制造执行系统 (MES)
适用行业
- 化学品
适用功能
- 离散制造
- 质量保证
用例
- 自动化制造系统
服务
- 系统集成
关于客户
Dow Chemical is a multinational corporation that manufactures more than 3,300 products at 156 manufacturing sites in 37 countries. The company delivers a broad range of plastics, chemicals, and agricultural products to customers in 160 countries. Many of their production facilities work with packaged, small-capacity containers that look alike from the outside but contain raw materials that are chemically different. The company's objective is to greatly reduce the risk of a process upset and move their operation from two to six sigma performance.
挑战
Dow Chemical manufactures more than 3,300 products at 156 manufacturing sites in 37 countries and delivers a range of plastics, chemicals and agricultural products to customers in 160 countries. Many production facilities work with packaged, small-capacity containers that look alike from the outside but contain raw materials that are chemically different. If a container is misidentified and the wrong material is added, a process upset occurs, adversely impacting product quality, material and asset utilization, or causing a health, safety and environment incident. Dow’s objective is to greatly reduce the risk of a process upset and move their operation from two to six sigma performance. Dow faced a number of challenges. Raw materials enter and exit the process at different times and from different locations. The control system is unable to differentiate between the various containers and materials, and human detection is unreliable.
解决方案
Dow developed a high-integrity material flow (HIMF) system, which is a method of ensuring that the movement of materials into and potentially out of a process position is authenticated. The HIMF system was built using two key products in the aspenONE MES suite: Aspen Production Execution Manager and Aspen InfoPlus.21 as an MES solution for procedural control. Connectivity between the MES solution and the warehouse data management system is essential for proper authentication of materials. As material is moved from the warehouse into production, the MES and warehouse systems share reference data. The MES system automatically generates a work request using Aspen Production Execution Manager, guiding the operator in material identification and retrieval. Material moved into production is compared with control system information through the use of a mobile human machine interface (HMI), which is a bar code scanner that’s integrated with a wireless mobile computer. Aspen InfoPlus.21 interfaces with the plant control system to confirm that the material the operator has scanned on the HMI at the production position is indeed the correct material for the recipe being executed. The automated workflow and product validation enabled by Aspen Production Execution Manager allows Dow to authenticate materials before they are used in the process.
运营影响
数量效益
Case Study missing?
Start adding your own!
Register with your work email and create a new case study profile for your business.
相关案例.
Case Study
Honeywell - Tata Chemicals Improves Data Accessibility with OneWireless
Tata was facing data accessibility challenges in the cement plant control room tapping signals from remote process control areas and other distant locations, including the gas scrubber. Tata needed a wireless solution to extend its control network securely to remote locations that would also provide seamless communication with existing control applications.
Case Study
Advanced Elastomer Systems Upgrades Production
In order to maintain its share of the international market for thermoplastic elastomers AES recently expanded its Florida plant by adding a new production line. While the existing lines were operating satisfactorily using a PROVOX distributed control system with traditional analog I/O, AES wanted advanced technology on the new line for greater economy, efficiency, and reliability. AES officials were anxious to get this line into production to meet incoming orders, but two hurricanes slowed construction.
Case Study
Wireless GPS Tracking & Security Monitoring
Enhancing the security of hazardous freight and ensuring compliance with Homeland Security’s Transportation Security Administration mandate that all trains carrying chemicals capable of creating a toxic inhalation condition are equipped with on-board safety monitoring systems.
Case Study
Field Device Asset Management For Chemical Company in China
Chinese chemical subsidiary of multinational corporation serves customers throughout the world. Sales offices and research and technology centers are strategically located to provide rapid response to customer requests. Just two workers were assigned to maintain thousands of intelligent instruments in three production units, so they could do little more than react to device issues as they appeared. This costly maintenance method inevitably led to unexpected downtime when a critical instrument failed. Plant management recognized the need to change from reactive to predictive maintenance for all assets, including instruments and control valves, but help was needed in implementing such a technology-based initiative.
Case Study
Industrial Workforce Mobility for Improved Safety & Operations
Huntsman Corporation, a global manufacturer and marketer of differentiated chemicals, undertook an aggressive program to eliminate injuries, product defects, and environmental releases at their Port Neches facility. Termed “Project Zero”, this program required a completely mobile solution to empower operations and maintenance personnel to capture defects, track work progress and make process and safety related decisions in real-time.
