Predictive Analytics for Production to Increase Man & Machine Efficiency

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Predictive Analytics for

Production

to

Increase Man & Machine Efficiency

www.ispredict.com | Copyright

Britta Hilt MD

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IS Predict & Scheer Group

Employees Turnover (million €) 184 217 300 350 0 500 2010 2011 2012 2013 Plan 16 20 27 40 0 50 2010 2011 2012 2013 Plan Locations P ro f. A .-W. Sch ee r

 Visionary, researcher and author of standard works for business information systems

 Member of the council for innovation and growth of the German Government

 President of the German Association for Information Technology (BITKOM 2007-2011)

 Ranked as 2nd most important German IT person (of 100) by Computerwoche magazin (after Hasso Plattner / SAP) in 2011

 Founder of international software companies IDS Scheer & IMC AG

 Sole Shareholder of Scheer Group GmbH

Germany | Saarbrücken, Freiburg, Hamburg, Munich

Australia| Melbourne Austria| Wien, Graz Benelux | Utrecht

France | Paris

Great Britain | London Rumania | Sibiu

Switzerland | Zürich, Basel Turkey | Istanbul

Ukraine | Dnepropetrovsk

2013

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Discover Your Data´s Secrets

3 www.ispredict.com | Copyright |

Efficiency increase

for man &

machinery

… then, finds the answers for you!

… and their answers are hidden, cut in pieces and incomplete in your data… If you have questions…

Automatic recognition of patterns & anomalies and Discovery of inefficiencies & their reasons

Analysis, simulation, prediction, recommendations & optimized control

Flexible use cases, i.e. maintenance, energy/resource savings, capacity/demand planning, order processing, …

What? How? For?

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More efficient production / Increased energy efficiency

Resource Intelligence – Projects

Increased efficiency for Man & Machinery thanks to Predictive Control

Optimized logistics

_`

_{Reduced maintenance costs}

The predictive, self-learning & flexible IT solution to increase resource efficiency

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Example Production incl. Simulation

Reduced Operational Costs @ Pellet Plant 1/3

Example Pellet Plant

Deliver

wood chips _{wood chips}Dry

Mill wood chips

Press saw dust into pallets Analysis 2:

Heat recovery adding value?

No permanent usage of both wood dryers required.

Analysis 1:

When reduced energy?

Fact Question

Which weather conditions are best to (not) run dyer in order to save energy?

Approach

Correlation analysis

Inter-relations among weather conditiosn / dryer performance / energy

consumption

Via heat recovery, air for dryer is heated to 20 degrees C How much energy can be

saved at wood dryer? Simulation

a) Energy demand was predicted with accuracy between 92 – 94 %. This means that influenced on energy consumption were discovered & analysis for saving

potentialas realistic.

b) Air temperature was simulated with 20 degrees Celsius. Energy demand was predicted.

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Example Production

Predictive Dispatching

Optimized Energy Dispatching

Varia tions in oven E ner gy fo recas t fo r energy planning & eff icienc y a nalys is Required energy Temperature Steel width Steel mass Time: 24 h Predicted Energy Required Energy Energ y De mand 1 month

Objective: Efficient energy dispatching and planned energy purchase in steel company Way: Enable planning for large energy consumers despite “not planable” consumption Problem: Highly volatile energy demand which does not seem to be caused by production. Data: Energy consumption & limited production (planning) data

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Example: Predictive Maintenance

Discover anomalies in machinery behavior i.e. in resource consumption

Individual demand-oriented maintenance via anomaly analysis

Objective: Increase efficiency via early information on (future) wear & tear

Way: Discover first and hidden signs when machinery does not run efficient anymore Condition: Individual & cost-reduced analysis per machine without additional sensors Problem: Strongly volatile energy demand, only engine energy data, no production data

Discovery of anomalies between 86% - 100%!

10 minutes: Engine run without disturbances 10 minutes: 51 disturbances due to breaks

Evaluate anomalies

Irregularities with various strengths and frequency

Early warning

Alert for technical service

Anomaly Details

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More efficient production / Increased energy efficiency

Resource Intelligence – Projects

Increased efficiency for Man & Machinery thanks to Predictive Control

Optimized logistics

_`

_{Reduced maintenance costs}

The predictive, self-learning & flexible IT solution to increase resource efficiency

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Contact:

[email protected]

+49 176 – 63 72 92 28

IS Predict GmbH

Scheer Tower | Uni Campus Nord D5.1 66123 Saarbrücken | Germany

Phone +49 681 – 96777-200, Fax +49 681 – 96777-222 www.ispredict.com