The future of manufacturing

Working smarter, not harder
BY CATHERINE DIAMOND

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The evolution of manufacturing has been fueled by revolutions. First, there was the transition from manpower to steam-powered machines. Then, thanks to the power of electricity, assembly lines and mass production capabilities were introduced. Years later, the computer transformed everything, and automation became the heart of manufacturing.

Today, we are in the midst of the fourth industrial revolution, commonly referred to as Industry 4.0. Broadly speaking, this refers to the widespread adoption of digital technologies that enable manufacturers to collect and intelligently use data. This information helps companies better understand their processes, which leads to significantly increased value for customers. For BASF, there is substantial potential across all functions and business areas to increase functionality, safety and savings by utilizing digitalization.

Smart manufacturing refers specifically to the digitalization efforts that lead to increased efficiency on a plant level. This includes both mobile devices and software platforms that help plants run smoothly and safely. Many of these technologies are already being used at BASF manufacturing sites, and with remarkable results. One example, out of Freeport, is the use of drones.

“This technology is advancing every single day, it’s really exciting. Every day we find new ways to use this.”

— Justin Harrington

Pilot in Command of Unmanned Aircraft Systems

Justin Harrington began learning about drones just as his time in the military was coming to a close. After he left the U.S. Air Force, he began working as a CUI (corrosion under insulation) inspector. As the company began to explore drones as a potential tool in the field, Harrington’s interest was piqued. Though there wasn’t yet a job posted that would require it, he began to pursue certification as a drone pilot. In August 2016, after months of study, he earned his license. It wasn’t until March 2017 that the position of Pilot in Command of Unmanned Aircraft Systems became available at Freeport. Harrington applied and was the top choice for the job.

“I love what I do,” Harrington said. “This technology is advancing every single day, it’s really exciting. Every day we find new ways to use this.”

Using drones has enabled those at the Freeport site to get an incredibly detailed view of the site while significantly minimizing environmental and safety concerns. The drones can fly over the site, providing comprehensive aerial views. They can also go into vessels and other equipment – all without the risk of injury to employees. Drones equipped with thermal imaging cameras can be used to inspect equipment for potential hazards without the need for costly scaffolding. And, if repairs are needed, scaffolding can be pinpoint accurate.

“Being able to find the leak quickly the first time we tried saved us all a lot of worry and angst and potential trouble.”

— Richard Kratzer

Project Engineer

Such was the case in Port Arthur after a leak was identified on New Year’s Eve in 2016. During a routine inspection, an operator noticed a small leak on the site’s super high pressure steam line. Using tablets equipped with thermal imaging cameras, a site employee was able to position himself on different platforms – without the use of scaffolding – and take multiple infrared pictures of the line. Based on those images, the section of the line that needed to have its insulation removed was easily identified and isolated. Overall, this technology saved the site two full days in repair time.

“Being able to find the leak quickly the first time we tried saved us all a lot of worry and angst and potential trouble,” said Richard Kratzer, Project Engineer. “This had everyone’s attention, including the plant manager, so getting to the solution quickly was very helpful.”

THREE PILLARS OF SMART MANUFACTURING

Augmented reality

Mobile devices, like tablets and smartphones, with applications that target maintenance and operations. Gives plant employees quick access to important information.

Predictive maintenance

Software that provides early warnings about equipment and assets. Reduces likelihood of unplanned repairs and failures.

Process optimization by big data

Software that performs advanced analytics and modeling to optimize plant processes. Results in improvements in yields, energy, waste and quality.

BASF was recognized for its Industry 4.0 initiatives at the 2017 Innovation Summit: Software Conference. Schneider Electric, organizer of the conference, presented BASF with an award for Digital Transformation Strategy. The implementation of industry-leading tactics – including predictive maintenance and augmented reality – have helped BASF to increase the efficiency and effectiveness of its processes while creating additional value for customers. At the conference in late 2017, guests were invited to learn about the next generation of industrial software innovation. The agenda included technology sessions, hands-on demonstrations and networking opportunities. Ravi Gopinath, Executive Vice President of Schneider Electric's Software Business, opened the day's general session with observations about the changes and challenges in industry today. "We are in the fourth industrial revolution,” he said. “This is the digital transformation that industries are moving to.” This revolution, Gopinath added, complicates existing business challenges. To succeed, industries must maximize its efficiency across the value chain, which requires continual optimization in real time. BASF was recognized for its role in this revolution. Upon accepting the Digital Transformation Strategy award, Uwe Hinsen, Vice President of Smart Manufacturing at BASF, discussed the use of technology, including Schneider’s PRiSM software, at some of the company’s facilities. Predictive maintenance, Hinsen explained, allows BASF to be proactive rather than responsive. Asset failures can be predicted, allowing inspections and maintenance to take place before a workflow interruption occurs. Augmented reality allows for increased efficiency and reduced errors. Mobile applications, including the use of tablets for recording equipment data (as opposed to traditional pen-and-paper), allow operators to be updated on equipment efficiency in real time. They also provide an opportunity for the collection of inspection data. "Data,” Hinsen said at the conference, “is the new oil. But it needs to be refined to create value."

BASF honored with "Digital Transformation Strategy" award

Schneider Award

The Smart Manufacturing Team from BASF 4.0 and NA 4.0 received the award.