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If you're trying to troubleshoot or optimize different aspects of your manufacturing process, consider adding an historian. This software is used to store and analyze vital process and industrial data. Historians fall into their own category in the world of industrial software due to the critical role they play in the success of analysis and decision making. Unfortunately many companies have lots of data, but do not use it effectively.
Many companies are looking for ways to determine the root causes of why their plant’s performance is not at its best on a consistent basis. For example, a plant manager may know that the plant is losing money because a process is taking an extra three minutes. However, determining why this process is taking those three extra minutes can prove to be challenging. Using historian software may provide the needed insight into this issue.
Historians are designed to capture and store a large amount of data from many different sources using disk space efficiently so that years of data can be quickly retrieved. For instance, OSI’s PI Historian can handle millions of points, archive thousands of events per second and quickly retrieve data from a million gigabytes of data (many years of data for most users!).
In a process control system, very common items that are historized include temperature, flow rate, pressure, level and other types of analog data. Also common is the historization of digital data, such as the output or feedback states associated with valves, pumps and other discrete control devices. Integration with other software systems, such as Laboratory Information Systems (LIMS), allows the comparison of process data with lab results.
There are many advantages to adding historian software to your manufacturing process. They include:
Visibility Across Different Systems/Vendors
If a site has multiple, separate systems, historian software can bring all those disparate systems into one view.
The historian can be used to analyze data for Overall Equipment Effectiveness (OEE) and batch cycle improvements.
Increased Availability of Data
Efficient Storage of Data and Quick Retrieval when Needed
A historian can store many years of data and make it available for immediate retrieval. Some of our customers have systems that were installed more than 15 years ago and all of the data since the initial installation can be easily retrieved for analysis and viewing. There are some installations where the historian can display historical data better than the control system. In one instance, operators actually preferred pulling up trends in PI Processbook because of the faster performance and the more convenient user interface.
Connectivity with Other Business Systems
By connecting the historian to business systems, it is possible to reduce downtime and more accurately report material consumption.
If you are interested in adding historian software to your manufacturing process or using the data you have more effectively, consider us. We have installed many historian systems including those from OSI, Rockwell, Honeywell, Wonderware and GE in a variety of industries, and our teams have interfaced with PLC and DCS control systems as well as a myriad of business systems. We work with a wide variety of industries including life sciences, chemical, food/beverage and consumer packaging, power, and pulp & paper. We understand the type of information your engineering, operations, technical services, maintenance, and business groups need. Big data is the wave of the future, don’t be intimidated, it is possible to use large volumes of data to improve your processes.