Bayer MaterialScience is one of the world’s largest producers of polymers and high-performance plastics. In order to create competitive world-scale structures and to continuously improve its manufacturing processes, Bayer MaterialScience (BMS) regards process data as a critical enterprise asset. To leverage this asset, BMS has closed an Enterprise Agreement with OSIsoft that is used to roll out the PI data historian to all of BMS’ major production facilities globally. This infrastructure is efficiently supported with remote monitoring by OSI’s NetworkOperationsCenter. It provides the basis for a set of applications that are being developed as part of BMS’ project “PIER – PI Enterprise Roll-out”. Examples that are presented in the talk include how process data is used to measure and reduce Bayer’s carbon footprint, how OEE for batch processes is reported and how a utility provider’s data is made accessible to BMS production plants.
Dr. Felix Hanisch studied Chemical Engineering in Dortmund and at Lehigh University in Bethlehem, PA (USA), and received his Dr.-Ing. degree from Dortmund University. He joined Bayer in 2001 as a process control engineer, where he held positions in process control technology (PCT) in plant engineering as well as in BMS’ production facilities. After leading the PCT Control Systems group at BMS’ site in Baytown, TX, from 2005-2007, he started the “Plant Optimization” group in the central PCT organization of Bayer MaterialScience AG, Leverkusen, which is responsible for process optimization and condition monitoring globally.