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过程控制与优化
概述
过程控制和优化 (PCO) 是在不违反过程约束的情况下调整过程以维持或优化一组指定参数的学科。 PCO 市场受到对节能生产流程、安全和安保问题的需求不断增长以及能够可靠预测流程偏差的物联网系统开发的推动。从根本上说,可以调整三个参数以影响最佳性能。 - 设备优化:第一步是通过检查运行数据以识别设备瓶颈来验证现有设备是否被充分利用。 - 操作程序:操作程序可能因人而异或因班次而异。工厂的自动化可以提供很大帮助。但是,如果操作员控制并手动运行工厂,自动化将无济于事。 - 控制优化:在典型的加工厂,例如化工厂或炼油厂,有数百甚至数千个控制回路。每个控制回路负责控制过程的一部分,例如保持温度、液位或流量。如果控制回路没有正确设计和调整,则过程会低于其最佳值。该过程的操作成本将更高,并且设备会过早磨损。为了使每个控制回路以最佳方式运行,识别传感器、阀门和调整问题很重要。已充分证明超过 35% 的控制回路通常存在问题。持续监控和优化整个工厂的过程有时称为绩效监督。
适用行业
- 运输
- 设备与机械
- 化学品
适用功能
- 离散制造
- 质量保证
市场规模
案例研究.
Case Study
NB-IoT Boosts Smart Bike Sharing
Ofo Bike sharing company wanted to improve its user experience by providing seamless network connectivity to its users where they can locate bikes and pedal away quickly exactly when and where they need one, but challenge is to avoid frustration if user finds difficulties in finding bikes, unlocking the bikes and making payments
Case Study
A.P. Plasman, Inc. Case Study
The A.P. Plasman Corporation manages multiple facilities with multiple processes, and when they were looking for an automation solution for their paint facility in Tecumseh, they were looking for a solution that could restrict access, deploy easily, and provide the ability to modify the application quickly to suit changing needs.
Case Study
Intelligently Managed Business Processes (Belcher Industries)
Belcher Industries can with right be classified as a high-risk business due to the nature of the work they perform. The risks include public liability and project risks including fixed cost, time penalties and product quality. Belcher experienced the following problems – often imposing serious risks for the business: • Belcher Industries are subjected to OSHA regulations. The absence of the necessary controls can result in penalties and increased premiums. Belcher wanted to ensure that the necessary controls are in place to contribute to a 100% no incident reputation. • Immediate productivity improvement in the workshop was a major objective. • Senior management often travels and improved control over task management and the ability to monitor work from off-site locations were high priorities. • Tasks were allocated to staff during meetings. These tasks disappeared from Meeting Minutes; they were often not performed within the time required; or they were misunderstood and the work performed was not according to specification. This resulted in additional labour and material cost as well as time lost. • Meetings were held with clients. Design specifications were agreed or decisions made, but there was no record of the supporting design documentation or the design agreements reached. This resulted in disputes with clients often to the detriment of Belcher. • Various registers are required to support ISO certification. Even though Belcher had all the registers in place the systems were islands and not integrated. • A key objective was to integrate the existing accounting system with the new solution. • The existing BelcherTrac system, that included only job control, quotes and purchase orders, became out-dated. Replacing this system with the XMPro driven BelcherTrac enabled them to integrate loose standing processes and registers into one solution.