Description
Dow Chemical's production facilities rely on small-capacity containers that look alike from the outside but hold chemically different materials. If a container is mis-identified and the wrong raw material is added, a process upset occurs, negatively impacting the process, product, and/or health, safety and the environment. Dow needed to eliminate any mis-identifications.
Customer Profile
Company Name
Crude Oil Production
Challenge:
Copy....
Solution:
Copy...
Benefits:
• Copy..
• Copy..
• Copy..
• Copy..
• Copy..
DowChemical Company
Specialty Chemicals
Challenge:
Eliminate mis-identification of
materials being moved into and out
of production
Solution:
Two key products from the
aspenONE PM&E suite: Aspen
InfoPlus.21
®
and Aspen Production
Execution Manager
Benefits:
• Issue and validate a set of actions
automatically
• Completely eliminate errors due
to mis-identification of raw
materials
• Assure six sigma performance
of the raw material management
work process
DowChemical Eliminates Raw
Material Management Errors for
Two Years Running
Global specialty chemicals producer turns to aspenONE
®
Production Management and Execution (PM&E) to implement
procedural control, efficiently moving raw materials and
avoiding process upsets.
Many of Dow Chemical’s production facilities rely on small-capacity
containers that look alike from the outside but hold chemically different
materials. If a container is mis-identified and the wrong raw material is
added, a process upset occurs, negatively impacting the process,
product, and/or health, safety and the environment. Dow needed to
eliminate any mis-identifications.
The specialty chemicals producer 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.
A key benefit of aspenONE PM&E is its capability to provide procedural
control in manufacturing work processes, so aspenONE PM&E was
implemented at Dow facilities to authenticate all materials and generate
orders to retrieve and load material into a process. The result has been
the total elimination of material management errors over the last two
years.
Worldwide Headquarters
Aspen Technology, Inc.
200 Wheeler Road
Burlington, MA 01803
phone: +1-781-221-6400
fax: +1-781-221-6410
[email protected]
EMEA Headquarters
AspenTech Ltd.
C1, Reading Int’l Business Park
Basingstoke Road
Reading, Berkshire
RG2 6DT United Kingdom
phone: +44-(0)-1189-226400
fax: +44-(0)-1189-226401
[email protected]
APAC Headquarters
AspenTech (Shanghai) Co., Ltd.
3rd Floor, North Wing
Zhe Da Wang Xin Building
2966 Jin Ke Road
Zhangjiang High-Tech Zone
Pudong, Shanghai
201203, China
phone: +86-21-5137-5000
fax: +86-21-5137-5100
[email protected]
© 2010 Aspen Technology, Inc. AspenTech
®
, aspenONE
®
, the Aspen leaf logo, and the 7 Best Practices of
Engineering Excellence are trademarks of Aspen Technology, Inc. All rights reserved. 2067-30-0810
About AspenTech
AspenTech is a leading supplier of
software that optimizes process
manufacturing — including oil and
gas, petroleum, chemicals, pharma-
ceuticals and other industries that
manufacture and produce products
from a chemical process. With inte-
grated aspenONE solutions, process
manufacturers can implement best
practices for optimizing their engin-
eering, manufacturing and supply
chain operations. As a result,
AspenTech customers are better able
to increase capacity, improve mar-
gins, reduce costs and become more
energy efficient. To see how the
world’s leading process manufactur-
ers rely on AspenTech to achieve
their operational excellence goals,
visit www.aspentech.com.
Avoiding Process Upsets fromMis-identified Materials
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.
aspenONE PM&E Chosen to Implement Procedural Control
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 PM&E 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 to 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), a bar code
scanner 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.
Material Management Errors Are Eliminated
Errors due to positioning incorrect raw materials into production have been
completely eliminated, moving this work process from a two sigma to near the
targeted six sigma operation. Aspen Production Execution Manager provides
the rigor of a programmed work procedure with automatic notification of a set
of actions to an operator’s hand-held device. Dow plans to implement this
solution in sites across the company.
About AspenTech
AspenTech is a leading supplier of
software that optimizes process
manufacturing — including oil and
gas, petroleum, chemicals, pharma-
ceuticals and other industries that
manufacture and produce products
from a chemical process. With inte-
grated aspenONE solutions, process
manufacturers can implement best
practices for optimizing their engin-
eering, manufacturing and supply
chain operations. As a result,
AspenTech customers are better able
to increase capacity, improve mar-
gins, reduce costs and become more
energy efficient. To see how the
world’s leading process manufactur-
ers rely on AspenTech to achieve
their operational excellence goals,
visit www.aspentech.com.
doc_542667707.pdf
Dow Chemical's production facilities rely on small-capacity containers that look alike from the outside but hold chemically different materials. If a container is mis-identified and the wrong raw material is added, a process upset occurs, negatively impacting the process, product, and/or health, safety and the environment. Dow needed to eliminate any mis-identifications.
Customer Profile
Company Name
Crude Oil Production
Challenge:
Copy....
Solution:
Copy...
Benefits:
• Copy..
• Copy..
• Copy..
• Copy..
• Copy..
DowChemical Company
Specialty Chemicals
Challenge:
Eliminate mis-identification of
materials being moved into and out
of production
Solution:
Two key products from the
aspenONE PM&E suite: Aspen
InfoPlus.21
®
and Aspen Production
Execution Manager
Benefits:
• Issue and validate a set of actions
automatically
• Completely eliminate errors due
to mis-identification of raw
materials
• Assure six sigma performance
of the raw material management
work process
DowChemical Eliminates Raw
Material Management Errors for
Two Years Running
Global specialty chemicals producer turns to aspenONE
®
Production Management and Execution (PM&E) to implement
procedural control, efficiently moving raw materials and
avoiding process upsets.
Many of Dow Chemical’s production facilities rely on small-capacity
containers that look alike from the outside but hold chemically different
materials. If a container is mis-identified and the wrong raw material is
added, a process upset occurs, negatively impacting the process,
product, and/or health, safety and the environment. Dow needed to
eliminate any mis-identifications.
The specialty chemicals producer 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.
A key benefit of aspenONE PM&E is its capability to provide procedural
control in manufacturing work processes, so aspenONE PM&E was
implemented at Dow facilities to authenticate all materials and generate
orders to retrieve and load material into a process. The result has been
the total elimination of material management errors over the last two
years.
Worldwide Headquarters
Aspen Technology, Inc.
200 Wheeler Road
Burlington, MA 01803
phone: +1-781-221-6400
fax: +1-781-221-6410
[email protected]
EMEA Headquarters
AspenTech Ltd.
C1, Reading Int’l Business Park
Basingstoke Road
Reading, Berkshire
RG2 6DT United Kingdom
phone: +44-(0)-1189-226400
fax: +44-(0)-1189-226401
[email protected]
APAC Headquarters
AspenTech (Shanghai) Co., Ltd.
3rd Floor, North Wing
Zhe Da Wang Xin Building
2966 Jin Ke Road
Zhangjiang High-Tech Zone
Pudong, Shanghai
201203, China
phone: +86-21-5137-5000
fax: +86-21-5137-5100
[email protected]
© 2010 Aspen Technology, Inc. AspenTech
®
, aspenONE
®
, the Aspen leaf logo, and the 7 Best Practices of
Engineering Excellence are trademarks of Aspen Technology, Inc. All rights reserved. 2067-30-0810
About AspenTech
AspenTech is a leading supplier of
software that optimizes process
manufacturing — including oil and
gas, petroleum, chemicals, pharma-
ceuticals and other industries that
manufacture and produce products
from a chemical process. With inte-
grated aspenONE solutions, process
manufacturers can implement best
practices for optimizing their engin-
eering, manufacturing and supply
chain operations. As a result,
AspenTech customers are better able
to increase capacity, improve mar-
gins, reduce costs and become more
energy efficient. To see how the
world’s leading process manufactur-
ers rely on AspenTech to achieve
their operational excellence goals,
visit www.aspentech.com.
Avoiding Process Upsets fromMis-identified Materials
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.
aspenONE PM&E Chosen to Implement Procedural Control
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 PM&E 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 to 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), a bar code
scanner 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.
Material Management Errors Are Eliminated
Errors due to positioning incorrect raw materials into production have been
completely eliminated, moving this work process from a two sigma to near the
targeted six sigma operation. Aspen Production Execution Manager provides
the rigor of a programmed work procedure with automatic notification of a set
of actions to an operator’s hand-held device. Dow plans to implement this
solution in sites across the company.
About AspenTech
AspenTech is a leading supplier of
software that optimizes process
manufacturing — including oil and
gas, petroleum, chemicals, pharma-
ceuticals and other industries that
manufacture and produce products
from a chemical process. With inte-
grated aspenONE solutions, process
manufacturers can implement best
practices for optimizing their engin-
eering, manufacturing and supply
chain operations. As a result,
AspenTech customers are better able
to increase capacity, improve mar-
gins, reduce costs and become more
energy efficient. To see how the
world’s leading process manufactur-
ers rely on AspenTech to achieve
their operational excellence goals,
visit www.aspentech.com.
doc_542667707.pdf