Process Performance Management
A New Way to Improve Production Processes
Our approach
What the project team delivers
- The team identifies potential areas for performance improvements and quantifies achievable savings by evaluating process information and data (reality check and potential assessment).
- The team defines process-specific key performance indicators (KPIs) to be monitored online to determine 24/7 efficiency, reliability and availability of process equipment and related operating conditions.
- The team implements model-based real-time applications for process monitoring, diagnosis and operator support, interfacing with shop-floor systems such as DCS, LIMS, PIMS and webbased production information systems.
- The team trains production personnel to establish appropriate workflows and to use performance related information efficiently in assessing current production status and making appropriate decisions for necessary process adjustments (e.g. set point changes) or maintenance tasks (calibration, cleaning and repair).
PerMonDO™ is a structured approach following the principles of the Six Sigma methodology, which is an accepted quality standard in many industries. Basically, PerMonDO™ projects are organized according to the DMAIC procedure – Define, Measure, Analyze, Improve and Control. Steps 1 to 3 are executed during a potential study, resulting in a quantitative evaluation of the savings potential and a concrete improvement plan describing all organizational and technical measures needed to achieve the predicted savings.
Steps 4 and 5 are the core focus of a subsequent improvement project resulting in new working procedures and online tools for process supervision and continuous process improvement. PerMonDO™ provides a number of advanced tools and problem solutions for offline data analysis as well as online monitoring applications.
By utilizing available process knowledge and integrating physical and chemical process models, these applications are much more effective than other popular empirical methods for process monitoring. This model-centric approach is a key feature of most of the tools in the PerMonDO™ suite, including:
- data reconciliation;
- controller performance monitoring;
- KPI calculation and monitoring;
- soft sensoring;
- model-based optimization.
PerMonDO™ projects are executed by an interdisciplinary team of experts from BTS, typically consisting of experienced chemical, control and software engineers and production specialists. This ensures the combination of fundamental knowledge in the areas of process design, optimization and control together with project experience that is required to ensure successful project execution.
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