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Home > Events > Orlando 2012: ARC World Industry Forum > Sustainable Operational Excellence Solutions

Presenting the Sixteenth Annual ARC World Industry Forum

Transforming Industry through New Processes and Technologies

February 6-9, 2012 - Orlando, Florida

Relentless Pursuit of Sustainable Operational Excellence through Intelligent Innovation

“Operational Excellence” continues to be a good overarching phrase to capture the primary pursuit of the process industries for the past decade.  This pursuit has been motivated by many factors including international competition, skyrocketing raw material and energy costs, shareholder pressure, and increasing regulatory and public relations pressure.  The decades long pursuit of operational excellence has been compounded by the global economic crisis and the increasing need for smart use of resources including energy, water, and raw materials.  Many feel the key to the future is innovation, which translates into running the business differently to achieve the sustainable returns that are key to long term profitability.  The challenge is to develop new strategies to deal with these challenges to ensure long term survival.

Operations Management and AutomationOver the last decade the state of the art of production management has been moving forward to an ever increasing automated state.  In the process industries operations management applications and automation systems are increasingly working in harmony.  Yet there is still a need for better management of these applications that often come from disparate sources including home-grown applications.

The amount of raw information flowing in the process plant has increased exponentially over the past decade.  Much of this information is still waiting to be turned into intelligence that can be used during the production of product to ensure that performance is meeting the goals of the business.

Still at the center of the activities in the plant is the process operator. They will still be needed 24 x 7 in the foreseeable future. But what is going to enable these operators to perform their future duties, as the systems surrounding them drive the plant to be more and more automated?  Compounding the problem is the demographics of the workforce.  As the workforce gets younger and less experienced, there has been a paradigm shift in the tools available.  Many of today’s process industry operations rely on technology and traditional operator training alone to ensure that processes run optimally and safely.  During normal operations, this may be sufficient.  However, the world is experiencing more and more abnormal events that test the industry’s preparedness.

Process industries are the largest and most intense consumers of energy.  While many are in the energy producing businesses, they all recognize that optimizing their own use of energy is essential to their future.  The efforts to date to reduce energy consumption have to be redoubled in coming years to meet not only profitability objectives, but also more stringent environmental regulations.  Companies that prepare now will have the edge on those that continue on the path they have been on.  ARC believes that we are just starting to scratch the surface when it comes to energy saving opportunities.

This program is full of information, technology, and most importantly, experiences to help you shape your own sustainable strategies.  You will be able to hear from other executives as well as discuss their views and compare them to your own on questions such as the following:

  • How can we create a lasting “culture of innovation” in our company?
  • What are the operational excellence lessons learned by successful companies?
  • Can energy and water be optimized and usage minimized at the same time safe operation is ensured?
  • How are leading process industry companies collaborating with technology suppliers to address lifecycle issues?
  • Which technologies will play an important role?  Are these technologies commercially available today?  What does “state-of-the-art” and “industry best practice” look like?
  • What standards exist today? Which ones should I pay attention to and why?
  • How do you develop the business case for making the necessary investments in people, process, and technology?  How are safety and environmental improvements being justified?  What is the ROI and payback?  How do you get the CEO, CFO, and CIO on board?

 

Who Should Attend

This forum program is a must-attend event for:

  • Operations, engineering, maintenance, purchasing, and automation executives of process industry owner/operators with responsibilities in process control, process safety, energy management, human factors and training, and other functions linked to achieving operational excellence.
  • Technology and service suppliers of automation, production management, process optimization, lifecycle management, cyber security, and other functions linked to process industry requirements.
  • Third-party companies that provide services to the process industries.
  • Executives that have new positions of managing departments and driving continuous improvement in an environment of evolving manufacturing technologies and cutting edge applications.

 

Agenda

Agenda details for this program are shown below.  Times and sessions are subject to change.
TitleUse SHIFT+ENTER to open the menu (new window).
  
Description
collapse Day : Day 1 PM ‎(2)
Control System Lifecycle Management: Migration and Sustainability

This workshop is the second in a series of workshops devoted to sharing end user experiences in managing the lifecycle of control systems.

Users are faced with a myriad of decisions to make throughout the lifecycle of their control systems.  As the end of the installed system’s life approaches, the decisions not only include the selection of the control system technology, but also how to manage the migration and how to sustain the new system that has been installed.  The new systems present both an opportunity to provide a greater degree of integration than perhaps the legacy systems provided.  This is also an opportunity to assess the traditional organization approach to managing the new system and technologies put in place.

This workshop will focus on issues, practices, and strategies that the workshop participants have or use to prepare for and manage the ultimate migration of their installed control system.  Owner operators that have gone through this recently will share their lessons learned.  In addition, the workshop attendees will share their practices in managing the new technology that comes with the newly migrated control system – particularly the roles of Corporate IT, Manufacturing IT, and Control Engineering.  Attendees will learn from peers what works and what did not work, while sharing their own experiences in managing their control system containing COTS technologies.

Control System Lifecycle Management: Migration and Sustainability Contd.
collapse Day : Day 2 AM ‎(2)
Transforming Industry: Keynote Presentations

Andy Chatha of ARC will discuss the top industry transformational technologies and processes for 2012.

Dianne Chong of Boeing will present some of the new technologies & materials used in 787 Dreamliner and how this plane will enhance our flying experience in the coming years.

Ron Guido of Johnson & Johnson will discuss what companies need to do to improve their supply chain integrity. 

Transforming Industry: Executive Panel Discussion
Dr. Leo Christodoulou will tell us some of the initiatives US Government has recently launched to help manufacturing companies improve energy efficiency throughout their supply chain.
 
After Leo's presentation, the Keynote Speakers will be joined by John Berra and Helmuth Ludwig for the panel discussion.  The main focus of this discussion will be to explore ideas how companies can transform their manufacturing operations through new innovative processes and technologies.
collapse Day : Day 2 PM ‎(3)
Making Production Management Collaborative
Some refer to the functions directly above the process control system as "CPM" or production management, others refer to these functions as "MES", and some call it "Level 3".  Whatever you call this increasingly important area, there are many challenges that can be solved by leveraging these applications.
 
The focus of this session is to address some of the major issues of this multi-supplier, multi-department, and multi-discipline area. These applications can interact with each other while keeping humans informed.  Attendees will learn how end users have been successful in creating a collaborative environment that improves operational performance in real-time.   
 
 
Enterprise Manufacturing Intelligence
With so much emphasis on making manufacturing more "intelligent" and driving operations to more and more efficiency, the need for instant information as to the performance of each manufacturing operation is critical.  Enterprise Manufacturing Intelligence (EMI), Operational Intelligence, and Manufacturing Intelligence are terms applied to the technology and practices available to tap into the vast amount of data available in the plant and exposing it as intelligent information with analytics, dashboards, and other visualization tools.  This information in context is more than process data.  It includes business information, operations data, and performance indicators (KPIs).  
 
Real-time analytics provides the user with the ability to perform dynamic or real-time calculations on real-time and historical data.  Analytics can help deliver information and results that enable the user to make real-time or near real-time decisions.  EMI is one of the fastest growing market segments of CPM or MES.  Whatever the term used for EMI, manufacturers in all complex or highly regulated industries are incorporating these technologies – from aerospace to pharmaceuticals to energy to refining.  Many manufacturers are addressing key complexities and challenges by implementing EMI solutions.
Security and Access Control for Industry

Physical security and access control are an important consideration today in the Internet-enabled industrial world.  Increasingly, government initiatives and tightening of regulations that mandate increases in security for plants, efficiency, and safety are all factors in determining the best strategy for your facility. 

This session provides insight into the latest trends and technologies for access control systems in manufacturing plants. Participants will learn about strategies for successful system implementation and optimization.  Since the results of implementing security and access control inevitably have an impact on production systems, this session is designed for leaders in operations-oriented systems.

collapse Day : Day 3 AM ‎(3)
Industry Transformational Technologies Executive Panel Discussion
This executive panel discussion will focus on top transformational technologies including: Analytics, Cloud, Mobile, Social, and 3D Virtualization.  Join this session to learn how industry leaders are extending applications to mobile devices, using social media and leveraging real-time data, business intelligence, advanced analytics, decision making, and collaboration tools on smartphones and tablets to drive performance to the next level.
Process Industries Operator of the Future
The role of the process operator is critical and continues to evolve.  Currently the role is characterized by long periods of monitoring, punctuated by short periods of intense spontaneous activity.  Changing demographics will drive fundamental changes in this role.  What will these changes be, how can we impart “The Best Operator” skills to new operators, how can we create a superior experience, and what tools will be available to support continuous performance improvement?
Industrial Energy Efficiency Coalition Session
Using federal legislation and programs to maximize the market opportunity for energy efficiency. Legislative and regulatory matters are key elements of the market environment that can enhance - or impede - success with industrial energy efficiency programs.  Many companies are insufficiently familiar with existing federal industrial EE programs and legislation and are not actively engaged in shaping these programs to ease industrial EE investment hurdles. Federal agencies and legislators need our engagement and help.
 
This session will demystify current federal programs targeted at industrial EE, including the DOE Advanced Manufacturing Office, ISO 50001, Better Plants Challenge, DOE Tools Portal, and Industrial Assessment Centers. It will also review 2012 proposed legislation that could benefit industrial EE investment for both suppliers and end users of automation and control equipment. Ensuing will be an audience dialog on how to shape federal programs and proposed legislation to be more effective and beneficial for EE investment.
collapse Day : Day 3 PM ‎(4)
Improve Asset Management to Drive Reliability--An Emerson Process Management Workshop
How can you ensure your asset management systems will drive improvements in unplanned downtime, maintenance costs, and employee productivity? Emerson‘s asset performance management expertise helps ensure you attain the results you need along with the proof to show your program is making a difference. We support your projects and help drive the results you require.  Through our worldwide network of more than 150 service professionals, we will implement an asset management program to align with your management objectives. We will develop an asset criticality analysis and asset strategies so your program clearly identifies and focuses resources on your most critical assets. Emerson’s experience in process plant operations and maintenance is amplified by our expert’s deep knowledge of asset failure modes. We work with you to drive decisions that will more effectively manage and maintain your most critical production assets. The result? Improved reliability.
Remote Operations Management

Secure remote access to automation systems and applications is now a necessity.  An increasing number of process operations are also located in remote and hostile environments, such as the ocean floor or the remote desert.  Historically, because of their proximity, the focus on operating remote industrial facilities has been to maintain steady-state operations despite frequent disturbances, with operators doing whatever was required to keep the facilities running and meet production schedules in a safe and environmentally acceptable way.

Although some remote facilities still operate in this mode, the next-generation of remote facilities will not.  The economics of steady-state operations are being replaced with a dynamic economic environment in which adapting to changing supply and demand are the norm.  This session will discuss the evolution, including both technology advancements and the ability to empower humans.

Energy and Water Management Strategies
In the process industries, reducing energy and water consumption can help a company improve its bottom line performance, while enhancing its reputation as a good corporate citizen.  In our increasingly resource-constrained industrial environment, implementing more efficient energy and water management practices will soon become a prerequisite for doing business. The system has to be highly integrated and collaborative to move to the next level of operation.  This includes providing the operator with the proper tools to be able to perform quickly and accurately.  This session will include discussions of the latest developments and industry experiences in energy and water management and optimization. 
MES/MOM:  The Key to 21st Century Manufacturing
Manufacturers are facing changes in their customers’ expectations, their partners’ capabilities, their workforce, and available technology.  Plant systems like MES/MOM can ensure operational excellence, product quality, and regulatory compliance, while enabling innovation, continuous improvement, and a more flexible response to changing markets.  This session features customer presentations focused on ‘lessons learned’ and ‘benefits’ of implementing modern MES/MOM systems.
collapse Day : Day 4 AM ‎(4)
Transforming Manufacturing with OPC UA: From Embedded to the Enterprise

Presented by the OPC Foundation

Industry standards have transformed manufacturing by providing a solid foundation for truly interoperable solutions.  The need for information integration in order to achieve manufacturing excellence is the business justification for suppliers to bring interoperable products to market — and end users to apply these products — in solutions that range from embedded devices to the ERP space. 

Manufacturing is enjoying a period of great innovation, with technologies that are evolving into a multitude of products. There is even talk of using smart consumer devices in applications that span industrial automation and beyond.  The key question is, how do all these opportunities for information integration and technical innovation come together into solutions that are secure and interoperable?  How does one take the multitude of applications and devices on a variety of different platforms and have them work together in a reliable, predictable fashion?

The OPC Foundation, in conjunction with end users and vendors, has been actively engaged in industrial automation, building automation, and smart grid applications that answer the integration challenge.  This two-part workshop presents an overview of the best industry practices to leverage OPC technology standards and infrastructure throughout the organization, from embedded components to enterprise planning systems.

This workshop is for end users, system integrators, OEMs, and suppliers who want to learn how their companies can gain a competitive edge with OPC UA solutions.  Find out how the OPC UA standard has become the interoperability foundation trusted by leading companies as their integration platform.

Improving the Industrial Standards Process
Everyone in industry “supports standards”, but more often than not industrial standards (rather than quality of their implementation) become a point of supplier differentiation.  Proof points include the unhappy history of the “fieldbus wars” and the three competing standards for industrial wireless sensing (ISA100.11a, IEC 62591/WirelessHART, WIA-PA).  Yet in an era of globalization and targeted cyber warfare, effective global standards for industrial communication (and especially for industrial network security) are critical needs.
 
Besides “supporting standards”, another point of wide agreement within industry is that standards development processes are broken and outdated.  They take far too long, cost way too much, and are much too likely to fail. 
 
In this panel session moderated by ARC,  a diverse group of stakeholders will discuss how to improve this process.  We will also discuss the best roles for end users, technical consortia, government, national and international standards development organizations.
 
OMAC Workshop Results and Activity Updates
Dave Odendahl and Bryan Griffen will each report on the results of their respective workshops and future action plans in the development, promotion, and deployment of machine tool and packaging machinery and line best practices and standards.
 
Paul Redwood of Church & Dwight will present the benefits PackML and other best practices and standards being developed by the OMAC packaging workgroup from a packers perspective.
 
Sid Venkatesh, chairman of OMAC, will report on the state of the organization and lead the annual face-to-face membership meeting.
Transforming Manufacturing with OPC UA: From Embedded to the Enterprise Contd.
Transforming Manufacturing with OPC UA: From Embedded to the Enterprise
Thursday, February 9, 2012, Workshop; 8:30 am—12:00 noon
Presented by the OPC Foundation
 
Industry standards have transformed manufacturing by providing a solid foundation for truly interoperable solutions. The need for information integration in order to achieve manufacturing excellence is the business justification for suppliers to bring interoperable products to market—and end-users to apply these products—in solutions that range from embedded devices to the ERP space. 
 
Manufacturing is enjoying a period of great innovation, with technologies that are evolving into a multitude of products. There is even talk of using smart consumer devices in applications that span industrial automation and beyond. The key question is: how do all these opportunities for information integration and technical innovation come together into solutions that are secure and interoperable? How does one take the multitude of applications and devices on a variety of different platforms and have them work together in a reliable, predictable fashion?
 
The OPC Foundation, in conjunction with end users and vendors, has been actively engaged in industrial automation, building automation, and smart grid applications that answer the integration challenge. This two-part workshop presents an overview of the best industry practices to leverage OPC technology standards and infrastructure throughout the organization, from embedded components to enterprise planning systems.
 
This workshop is for end-users, system integrators, OEMs, and suppliers who want to learn how their companies can gain a competitive edge with OPC UA solutions. Find out how the OPC UA standard has become the interoperability foundation trusted by leading companies as their integration platform.
Dave Woll on Future of Automation
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