I-DS InduSoft Dispatching System

The I-DS dispatch control system is the basis for the creation of an integrated production control system that integrates data on technological processes, energy resources, quality, agreed material balances. I-DS is an advanced solution developed in accordance with modern trends in the development of dispatching systems for production processes.

2016: Inclusion in the Register of Domestic Software

In October 2016, LIMS I-LDS software products and the I-DS Dispatch Control System developed by InduSoft included in the Unified Register of Russian Programs for Electronic Computers and Databases.

The register was created in accordance with Article 12.1 of the Federal Law "On Information, Information Technologies and Information Protection" in order to expand the use of Russian programs for electronic computers and databases, confirm their origin from the Russian Federation, as well as in order to provide copyright holders of programs for electronic computers or databases of state support measures. The register contains information about all software that is officially recognized as originating from the Russian Federation.

2014: I-DS Capabilities

Modern information technologies provide an opportunity at a new level to organize the interaction of production and dispatch services of the enterprise. Automation of dispatching control allows you to create an operational notification system for specialized services of the enterprise, monitor the implementation of dispatching instructions, form verified reports on the state of production and the company as a whole for all geographically distributed production facilities.

The company "InduSoft" systematically develops and improves solutions for the automation of production management processes, focusing as much as possible on the specifics of domestic enterprises. The I-DS (I-Dispatch System), a specialized software product developed by the company's employees, is a comprehensive solution for automating all components of the dispatch control and control process, including:

• technological monitoring;
• development of dispatch reporting;
• Manual data entry and management
• Event management
• production accounting.

Technological monitoring

The main task of automation of technological monitoring processes is to provide all services of the enterprise with operational information on the state of production. To accomplish this, I-DS automates the processes of collecting, processing, storing data, presenting current, historical, and aggregated process progress information. The user interface is customized for the needs of each specialist and allows you to access both standard approved forms of displaying production information, as well as dynamically generated by the user tables, trends, mnemonic diagrams and diagrams.

The I-DS includes a set of templates developed by InduSoft specialists for multi-graphic presentation of production information:

• product schemes of the enterprise;
• analysis of plan execution by production facilities;
• inventory, balances, work in progress;
• quality of raw materials, semi-finished products and finished products;
• power resources distribution diagrams;
• energy efficiency, equipment condition, etc.

Dispatch reporting

One of the most important processes in production management is production reporting. Reports are the most common and formalized tools used by enterprise specialists to analyze the state of production. At the same time, reporting is a universal means of exchanging information between workshops, production and enterprise services.

I-DS software fully automates production reporting processes at each level of production management: sectional, workshop and offsite. At the same time, I-DS already includes ready-made templates of the most common reports: "Worksheet," "Shift Operator's Working Log," "Daily Workshop Summary," "Plant Material Balance," etc.

Manual Data Entry and Management

Manual entry of missing data, adjustment and approval of process parameters, authorization of self-accounting indicators by operators and dispatchers of various levels are basic processes in enterprise dispatching. The I-DS software product contains all the necessary tools for the organization of AWS operators and dispatchers at any level of the enterprise, designed for manual data entry, correction and approval.

I-DS uses special visual workflow configuration tools (called workflows or flowcharts) to formalize data entry and processing algorithms. These tools allow you to clearly describe (build) and regulate the processes of automated collection, manual entry, correction, approval and publication of accounting and reporting data used by a large number of process facility operators, production service managers. The description of standard procedures allows you to quickly influence these processes, adapting the system to changes in technology or production organization.

Event Management

Production management processes are largely of an event nature. Dispatchers and operators of various levels register events: start-up/shutdown of equipment, mode changes, start/end of material movement operations, incidents, emergency situations, excess of specific energy consumption, overspending of raw materials or reagents, etc. I-DS in this case automates the main functions for identifying events, classifying and responding to them in accordance with production instructions. At the same time, I-DS provides:

• automatic identification of events (exceeding parameter limits, parameter change rate) according to previously described algorithms (for example, dynamically calculated parameter limits, etc.).
• automated generation of dispatch commands from the higher level of control to the lower level and control of their execution;
• registration of events, emergency and emergency situations by specialists of the enterprise and, if necessary, notification of adjacent and higher divisions in accordance with the approved regulations and instructions;
• storage in a single database of all classes and types of events by enterprise;
• acknowledgement, assignment and maintenance of genealogy of events.

Notification tools (SMS, e-mail, sound alarms), visualization on mnemonic diagrams, event history analytics allow enterprise specialists to be sure that they will not miss a single event and will be able to quickly decide how to respond to a particular situation.

Monitoring of compliance with technical regulations

Regulations allow manufacturers to guarantee the quality of commodity products under cost limits. At each enterprise, in accordance with official duties, various divisions develop: standards for quality indicators of raw materials, semi-finished products, marketable products, norms of technological modes, norms of consumption of raw materials and reagents, norms of specific consumption of energy resources. Continuous and full-scale monitoring of all regulations, norms and modes can be carried out only by automated method.

Automation of monitoring of deviations of process indicators from regulatory standards provides an opportunity for a wide range of users to track deviations from technological, environmental standards, the regulatory level of product quality, energy consumption standards, materials and reagents. I-DS also allows the user to create individual norms of the processes of interest, templates for the modes of repeated processes, according to which the system will create group or personal events and alarms. The accumulated event history allows you to quickly analyze the behavior of controlled processes without spending time looking for problems by trends or logs.

The generated alarms about deviation of the monitored parameters from the set values ​ ​ at the pace with production are sent through all possible notification channels. Various tools have been developed for monitoring and analyzing events and alarms: lists with the ability to apply filters by parameters and set time limits, an alarm tree, and analytical reports.

Dispatch Logs and Tasks

The efficiency of the dispatching system of large geographically distributed facilities depends on the organization of interaction between dispatchers of various levels and process facility operators. Automation of dispatching logs, task execution management reduce the time spent on communications between different levels of control and the risks of the "human factor" influence when transmitting commands.

Dispatching tasks and log entries are one of the types of production events processed according to their own algorithms and configurable workflows, which allow you to flexibly describe the processes of registration, determining the status of the task, grouping into the job tree, logging (logging). Standard event tools reduce the time spent by dispatching services on logging.

Handling Abnormal and Emergency Situations

Prompt response to operational emergencies and emergencies is one of the key tasks of dispatch services. Timely detection of extraordinary events and clear adherence to regulations and instructions is the determining factor in the prompt localization and prevention of further development of emergency and emergency situations dangerous for personnel and process equipment.

Automation of work processes in emergency and emergency situations:

• provides registration of abnormal situations;
• Simplifies the classification, assessment and determination of the event importance category
• enables support of dispatching decisions in case of abnormal and emergency situations;
• provides notification of responsible specialists of the enterprise in accordance with the approved regulations;
• simplifies monitoring of development of abnormal and emergency situations;
• stores the event archive for "flight analysis" with the ability to apply any necessary documentation in the formats *.pdf, *.doc, *.jpg, etc.

Mass calculation as per GOST

The reliability and legitimacy of material and energy flow records in a distributed system for collecting information from various sources determines the quality of production records. At any enterprise, the task is to ensure the uniformity of primary measurements, as well as minimize the influence of the "human factor" on the calculation of the mass of reserves, consumption of raw materials and energy resources, the production of semi-finished products and marketable products for each technological facility and for the enterprise as a whole. The main approach is to collect primary measurements from the instrumentation level and centralize mass calculations in a single server of the dispatching system - which ensures the unity of measurements and rapid change of calculation algorithms when new regulatory documents are issued.

InduSoft specialists have developed and certified as part of the general solution a server module for calculating I-DS/CM masses, designed to build and execute computational algorithms according to GOST, MI and local methods for specific enterprises. Thus, the function of finding the method of calculating (and actually calculating) the required mass and energy values ​ ​ from some known parameters (for example, pressure, pressure drop, product temperature, laboratory density, etc.) is realized by:

• determining techniques and corresponding input parameters by which to calculate an output parameter of interest for a particular product;
• specifying units of measurement in which the calculation and automatic conversion of values within the calculations unique to the enterprise takes place;
• check of calculations and correctness of input of initial values;
• support of conditional settlements;
• check the limits of valid values.

The mass calculation system allows you to connect additional modules with calculation methods developed by the company's specialists.

Material Movement Accounting

In order to manage materials and inventory efficiently, the company needs to record the movement of raw materials, semi-finished products and finished products along the entire production chain at the pace of production - to ensure that:

• dynamic accounting of raw material receipt;
• dynamic accounting of directions and flows of transfer of raw materials, semi-finished products and products by enterprise;
• dynamic accounting of the amount of raw materials, semi-finished products and products in containers;
• operational calculation of the availability of raw materials and products at production facilities and residues by tanks;
• Calculate the mass of material transfer operations.

Depending on the level of automation of tank farms, warehouses, etc., information on the execution of operations of the movement of raw materials and products (time of the start and end of the operation, object - source, object - receiver, mass) can be entered automatically or manually. If there is a sufficient level of automation, movement information can be generated automatically.

To automate accounting operations, a special I-DS/MS solution provides the operator with a set of dialog boxes for entering values ​ ​ of parameters characterizing the state of the tanks and fixing the operation of moving materials through tanks, warehouses, silos. The program uses a number of algorithms to calculate the masses of the operations of moving materials at a pace with production. The solution implements a flexible reporting system for operators and dispatchers of the enterprise.

Monitoring of equipment operation

A number of tasks of dispatch control also include the task of automating the processes of monitoring the state of the main and auxiliary equipment, which directly affects the execution of the production program. Automation of the process of monitoring the operation of equipment provides the ability to carry out detailed monitoring of the state of objects by:

• publication of indicators of equipment condition for operational monitoring of equipment units/groups (subdivisions as a whole);
• use of alarms, comments, developments, repair plan/facts as initial data;
• generation of each of the indicators according to a separate algorithm;
• implementing the possibility of changing the composition of indicators (including changing their calculation algorithms).

The obtained values of equipment performance indicators are used to calculate the indicator of its technical condition - operational readiness. Automated downtime accounting is also implemented, providing:

• diagnosing the occurrence of elementary downtime associated with a complete shutdown of equipment or a significant decrease in performance;
• visualization and signalling of occurrence of elementary downtime on mnemonic diagrams;
• Recording downtime with process personnel by describing complex downtime
• input of primary causes of equipment shutdown;
• Transfer reported outages for analysis to a ERP system or EAM class system.

Calculation of KPIs

The informativeness and sufficiency of the existing system for assessing financial and production indicators at the enterprise directly affect the quality of management decisions. Key performance indicators () are actively used to assess the efficiency and efficiency of the production facilities of the enterprise (process plants, production facilities) and organizational units involved in the production of individual divisions. KPI

One of the tasks of the automated production dispatching system is to generate operational and reliable data for the information content of production efficiency indicators from the level of a separate technological facility to the level of the enterprise as a whole.

I-DS software provides automation of the data collection process for KPI calculation, automation of KPI calculation processes and organization of a single information space with the possibility of visual representation of KPI in the form of business graphics and analysis of factors of influence on indicators.