Process Data Analytics

Process Data Analytics software and Yokogawa's analytical services are quality stabilization solutions that can help companies stabilize and continuously improve the quality of their products. Process Data Analytics enable you to understand the situation of your plant more deeply by analyzing process data from the view point of 4M (Material, Machine, Method, huMan).

 

Table of Contents

New Update
Outline of Process Data Analysis 
What is Process Data Analytics (PDA) 
Related Information 


Key areas for Operational Excellence Transformation

Operational Excellence Transformation is Yokogawa and KBC’s co-innovated portfolio of solutions and services.We provides comprehensive solutions for business automation in all four areas using consulting and digital technology.

Asset Operations and Optimization

Asset Operation and Optimization deals with realizing the potential of physical assets by pushing throughput and maximizing the production of the highest-value products, while minimizing variable costs, such as energy. It ensures small and large capital expenditure projects are delivered on time and on budget, to achieve growth and meet environment requirements. Through these competencies, it will be possible for companies to take full advantage of their physical assets. Yokogawa’s Asset Operation and Optimization solution leverages industry-leading technology to generate precise operating information to increase operator insight, ultimately leading to improved performance and profitability.

Key Operational Competencies in Asset Operations and Optimization

  • Asset Strategy: Define the requirements of plant capacity, operability and production to align with corporate strategy.
  • Asset Improvement: Improve plant profitability by expanding plant operating window and/or adding/modifying plants
  • Asset Optimization: Optimize the plant by enabling shift teams to execute activities as per plan and within operating window boundaries
  • Asset Operations and Process Control: Operate the plant by enabling shift teams to implement plans effectively and manage abnormal situations
  • Capital Projects Delivery: Screen options, engineer and deliver capital projects that are cost-effective, timely and fit for purpose 

With our track record of providing project execution and thorough lifecycle services and KBC consulting, our customers can obtain practical and deep insights on maximizing their physical assets. Together, we aim to contribute and actualize improvements not only for profitability, but also for overall safety, operability and reliability.


·Supply Chain Optimization
- Optimize management of supply, whether oil in the ground or feedstocks for a refinery or chemical asset, in light of product market demands. This provides operators with the agility to take full advantage of market conditions.
·Operational Risk Management 
- Reliably control safety, health and environmental risk at a personal and process level. This assures the robustness required to avoid catastrophic losses.
·Asset Management and Integrity
- Confidently ensure asset reliability and availability, whilst controlling maintenance costs. This assures the asset always meets expectations and is always available to capitalize on short term market opportunities. 

 


New Updates

Case Study

2019/6/15
A new success story has been released for a consulting service with Yokogawa Data Analytics solution
Featured Reference: Stabilization of Process and Improvement of Operation through Process Data Analysis

 


 

Outline of Process Data Analysis

Process Data Analysis aims at creating value from process historian Big Data by classifying, organizing and interpreting process data accumulated in a plant (big data) according to 4M* conditions. Recently, in the theme of AI and IIoT, more and more companies have introduced process data analysis for quality improvement, yield improvement, and production stabilization.
* 4 M: Method, Material, Machine, huMan


However, even if you actually try to analyze the process data on site, it will not work soon. This is because, for example, the following issues prevent the utilization of process data.

 

 

Issues Commonly Faced When Customers Try Analyzing Their Own Process Big Data

Process Data contains information 4M information which implies when and how 4M condition is changed.

Complexity of process data

 

Analyzing process Big Data is time-consuming because it is necessary to consider the process design concept and 4M* condition when extracting and preprocessing data.

 

Situation of analysts

  • Typically, customers try to analyze their data using non-specialized software for process data. However, using such tool will make analysis even harder and will cost a lot of time and efforts.
  •  Customers often have less or no internal data scientists who are familiar with analysis work. In addition, most of analysis time is spent on thinking of next action of analysis.
     
Data analysts know what to do next in data analysis work, but a person who is not familiar with data analysis usually takes time to consider what to do next.

What is Process Data Analytics (PDA)

 

Process Data Analytics is Yokogawa proprietary and field-proven data analysis software which is designed and developed from the broad know-how of more than 100 consulting projects to customers in the process industry, and it allows process engineers to analyze and create valuable insights from their plant Big Data in quick and efficient manner.

 

Functions of Process Data Analytics

Process Data Analytics has powerful and user-friendly functions for quick analysis of process data. These functions can be tailored out to allow customers not only conduct analytical tasks on their plant Big Data, but also plan and implement countermeasures efficiently. Below is a list of some of these functions:

  • Graph display function
  • Data extraction / labeling function
  • Time difference / phase difference adjustment function
  • Trend data pre-processing function
  • MT analysis function

 

PDA enables you to preprocess your trend data according to 4M changes, and interpret data with various useful functions specific to trend data.

* Customers with little experience of data analysis can order the service of analysis consulting done by YOKOGAWA specialized consultants.
 

Details

  • Graph display function

All trend graphs are displayed instantly at the time when process data is imported. In addition, other chart types that are useful for data evaluation such as histograms, scatter plots and overlay graphs can be created and displayed easily.

  • Data extraction / labeling function

Based on the manufacturing site 4M conditions, which is included in the process data, data can be partitioned, labelled, stratified and compared to discover and highlight useful insights about process changes.
Examples of 4M change: Change of raw material lot, switch of MAN / AUT mode, facility stop, sensor failure, etc.

  • Time difference / phase difference adjustment function

Process Data Analytics has a function to adjust the phase difference and the time difference between data of relevant process tags. Performing such adjustment makes is essential to make comparison meaningful; because there is often a time shift/difference between process tags which relate to each other physically or chemically.

  • Trend data pre-processing function

Process Data Analytics has a preprocessing function to eliminate periodic fluctuation and measurement error contained in process data. This function makes it possible to extract the characteristics of the data, display the trend on the software and confirm it.

  • MT analysis function

Process Data Analytics has discriminant analysis function for quality engineering called Mahalanobis-Taguchi method (MT method). By using the correlation analysis of such method, the relationship between normal data points against abnormal data points can be verified quantitively.
 Process Data Analytics has other functions for database linkage, such as linkage with Exaquantum, OSI soft's PI System, and MathWorks' MATLAB.


 For more details, please reach us by following the information at the bottom of this page.

Who Should Buy This Software?

  • If your top management has set goals to utilize Artificial Intelligence; but you do not know how to start applying it to field to solve every day’s problems or to improve your process.
  • You were assigned the job of analyzing large amount or complicated process data, however you realized that there are many conditions that one need to take into consideration before dealing with such data.
  • R&D department has developed a new anomality detection system, but you need to test it before deployment with field data. 

* Company names and product names described on this page are trademarks or registered trademarks of their respective companies.


Related Information

Case Study Back Number

Stabilization of Process and Improvement of Operation through Process Data Analysis

Overview:

MGC Mizushima Plant selected Yokogawa's PDA to achieve one of its improvement activities.
MGC has successfully stabilized the process and reduced the operator work load.

Overview:
  • Sumitomo Seika achieved the quality stabilization by cross-department project.
  • The fusion of process knowledge and data analysis technology was a key to the success.
Industries:
Overview:

Yokogawa has a long history of co-innovation in process control and safety.  Combined with recent strategic know-how and IP-rich acquisitions, the company can now apply its deep domain expertise to create a differentiated offering in the industrial automation space. From analog or manual data being digitized to the complete digitalization and improvement of work process, with recently-acquired KBC, Yokogawa is helping industrial organizations transform their businesses to help meet both current and future challenges.

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