Home > OSI PI > Would PI Batch be useful for your company?

Would PI Batch be useful for your company?

Many companies hear the word Batch and figure it’s not for them, especially industries with continuous manufacturing (ex. power). After a little education, companies come around and soon tap into the power of visualizing their processes from a Batch perspective.

Through my 30 yrs working with Batch, my participation on the ISA S88 Batch standards committee, and exposure to a diverse set of industries, I have found that every industry can improve their processes and product by incorporating PI Batch into their analysis.

In simplistic terms: PI Batch is a convenient way to select time ranges in order to compare time-series data. These comparisons can be different time ranges in the same process/machine or between different processes/machines.

  • Product Quality from a run last night against a known good run (golden batch) last month
  • Product yields in the Summer versus the Winter
  • Paper machine A against Paper machine B
  • Night shift against Day shift
  • Product complaints against formulation A versus formulation B
  • Profitability with manager A versus manager B

It’s the creative implementation of this simple concept that makes it so powerful! PI Batch can be applied in ways that people never thought of:

  • Tanks: Mixing a Vessel of material, blending products together
  • Silos: Stratification of dry ingredients in a hopper (ex. pellets)
  • Roll Stock: Making a roll of paper, cutting up a roll, splicing a roll
  • People: Shifts of workers (days vs evenings vs nights), workers at different locations
  • Raw Materials: Usage of a given raw material lot (a rail car of coal, color dye lot, supersack of silver nitrate)
  • Production metrics (downtimes, production holds, throughput, recycle volumes)
  • Quality metrics (product grades, reject rates, sampling plans)
  • Financial metrics (profit level, expenses, overtime)
  • Seasonality (Spring, Summer, Fall, Winter)
  • SOPs: Standard Operating Procedure revisions
  • Maintenance Cycles: Runtime of a piece of equipment (turbine generator online, a motor running until the next rebuild)
  • Product Yields: Which field produce was grown in
  • Timeframes: Day of the week or other fixed timeframe (24 hr production of power)
  • Suppliers: Which raw material supplier or source location

Most people are surprised to hear that you can run multiple batch schemes on the same equipment. You can have one batch configuration for equipment, another for seasonality, another for shifts, and another for raw material supplier… all against the same part of your process. You simply choose the ‘particular flavor of batch’ that you are interested in looking to compare; you can switch between different batch definitions based on your finds:

  • Start by looking at production rates and/or yields
  • Switch to downtime analysis
  • Cross-reference to shift analysis
  • Verify there isn’t additional influence from seasonality

PI Batch is easy to configure and if you don’t find a particular configuration useful, you can remove it. Not only do you save time quickly find a set of time ranges, it can help you visualize your product and processes to identify issues, which provide a mechanism for continuous improvement.

So it doesn’t matter if you are a traditional batch process, a transitional process with both batch and continuous, or a totally continuous process, everyone can benefit from the use of OSISoft PI Batch.

Give us a call now: 828-862-6667 x300 or send an email

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