GRK Wonderware MES

2019

The Ekzeplent company entering into the OMEGALLIANCE group successfully put into commercial operation the system of operational production management on Bystrinsky GOKE. Large-scale works on creation of unified information environment which had to integrate in itself all data on production processes were conducted with the middle of 2017 in parallel with construction of plant. Thanks to accurate and harmonious work of a project team of Bystrinsky GOKA and professionals from Ekzeplent all works on creation of a system of operational production management were executed till the end of 2018.

Bystrinsky GOK – the project, priority for Norilsk Nickel, on construction of modern mining and processing works from scratch. The company management set the task of construction of the enterprise using ultramodern production technologies and managements for contractors at once. Specialists of Ekzeplent developed and implemented the concept of the digital enterprise on the basis of the following principles:

• Increase in safety of conducting technology works, decrease in quantity of emergency and emergency situations and terms of their elimination;
• Ensuring accomplishment of production plans;
• Minimization of need of permanent presence of personnel on remote objects;
• Decrease in labor input of maintaining reporting documentation (dispatching reports, official reports, reports);
• Ensuring correctness and data consistency of the analytical reporting;
• Reduction of labor costs on data collection for drawing up the analytical reporting under balance of metals and to a material balance;
• Ensuring access to data on production work to external systems and consumers.

The solution of assigned tasks required use of the best world practices and experiment of Ekzeplent company on development and deployment of the systems of operational production management of the class MES for large industrial enterprises. As a reference platform for implementation of a system products of Aveva company (Schneider Electric) were selected. Solutions of a line Wonderware more than once proved the efficiency in practice, providing a fast investment payback, potential of growth and scaling, and the most important is an optimization of production costs and increase in profitability of business due to use of digital technologies.

In the project progress the Ekzeplent command met a number of calls. On Bystrinsky GOKE, as well as on any object under construction, incompleteness of initial data at a design stage, lack of regulations of production processes, the described business processes and inaccuracy in the description of target processes took place. Therefore at design solutions were selected the most flexible scenarios and approaches allowing to scale and change easily and quickly the solution depending on evolution of requirements of business to management of production processes.

Important component of the project – integration of the production functions implemented by a system and business processes of the Customer for what at a system design the principles of the model focused approach - Model-Driven MES were used. Within this approach the business processes operating at the enterprise are digitized, implemented in the form of models (business rules and user interfaces) and are used at accomplishment by the system of production functions.

For implementation of the principles of Model-Driven MES the integrated solution of Wonderware MES + was used by Skelta BPM which integrates in itself functions of the systems of operational production management (MES) and Business Process Management Suite (BPM).

When implementing the project it was necessary to solve problems of data collection from a set of the systems of subordinate level of different producers - from an APCS and local automated control systems to specialized information management systems for shipment of finished goods.

In a project deliverable "GRK "Bystrinskoye" received a centralized system of operational production management which allows:

• Messages permanent automatic monitoring of technology processes of the enterprise to register and notify operation personnel on deviations from optimal operation modes;
• Control and manage support entities of water supply, heat supply and power supply from the central console of management of auxiliary productions;
• It is automated messages reporting documentation on the basis of these metering devices and the APCS systems, to control processes of providing necessary data by production services and timely providing reporting documentation to interested persons;
• Exercise a constant control of production indicators and control of accomplishment of production plans;
• To automatically control integrity, consistency and accuracy of the data when forming dispatching reports, maintaining the analytical reporting under performance, practices and equipment downtimes;
• Create a basis for providing production data to the adjacent systems of the enterprise for drawing up the analytical reporting.

"The full-function system of operational management started on Bystrinsky GOKE is designed to become the base of modern Digital manufacturing enterprise, - Shinyaev Vladimir Alekseyevich, the project manager of project office of the Chita project of PJSC Norilsk Nickel MMC.-combining Construction of GOKA and Parallel Creation of a Complex Numerical Control System by the Enterprise, We Intend to Reach Required Production Capacities in Most Short Time. Thus, We Are Going to Use the Wide Potential of Digital Instruments. We Will Develop Further Functionality of a System within Our Strategy for Increase in Operational Efficiency noted.

Further harmonious scaling of the solution, inclusion of new business processes is provided. In plans for 2019 - to solve problems of integration with adjacent production systems, such as management system for mining operations, laboratory information system (LIMS) and also schedule system of resources of the enterprise (ERP).