Big Data, Big Analytics, Business Intelligence, Manufacturing Intelligence or MIS (Management Information Systems) - whatever you want to call it, there is no doubt that the challenge of collecting and analysing large amounts of data has become a major concern and trend for business. But this trend is not new for manufacturers, many of whom have been collecting and utilising 'Big Data' for years through their process data historian.
Manufacturers are not known for their willingness to embrace new, cutting edge technologies but they have embraced the use of process data historians, a tried and tested technology that is ideal for collecting the mind numbingly huge volumes of data that is essential for the visualisation and effective running of process plants. An example of the kind of data volumes I am talking about comes from one of our major customers who has used Wonderware Historian for over 10 years. They are a biochemical manufacturer and use Historian to collect data from 7 gateway servers every 15 seconds. This equates to over 75 million data points collected every day! Very Big Data indeed. This data is then used to create dashboards that enable the monitoring of batches and the optimisation of processes and has been instrumental in improving the efficiency of the site and increasing output by 75%.
But not all manufacturers are using their data as strategically as our biochemical manufacturer. Many customers have already invested in a data infrastructure but don’t realise the extent of the data they are currently collecting and how it could be analysed and applied for business improvement. Simply put, they have a huge data asset that they are not making the most of. In these cash strapped times where the emphasis is on increasing productivity without increasing capital investment, it would make sense to squeeze as much benefit from this data asset as possible.
Indeed there is an increasing view that data intelligence will differentiate the successful organisation in future. This is particularly true for manufacturers who face unique challenges. Many are fighting for survival, not just against competitors, but internally against other sites in other countries with a lower cost base. The demand here in the UK to manage operations in an environmentally and socially responsible way coupled with the rising costs for labour, materials and energy put many UK manufacturers at a distinct disadvantage.
But that’s where SolutionsPT comes in. We have a track record of helping manufacturers use the data from their process data historian to achieve a competitive edge. We can help you to audit and assess your current data infrastructure or help you to specify these systems from scratch if they are not currently in place. Then, depending on what you would like to achieve, we recommend the appropriate tools to analyse, report and present the data as useful information and disseminate as appropriate to the wider organisation.
Often simply making information available to operators can help employee engagement and drive improvements. Clearly, the easy availability and analysis of data can transform the way a company works and enable manufacturers to better understand their plant and predict and manage performance. With so much of this data already available and locked in process data historians, accessing it is a lot easier than you think.
Next Week: 101 uses for your Data Historian
Sue Roche - General Manager, Wonderware UK and Ireland, SolutionsPT
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