Dow Chemical had a Very Big Data Problem – they collected huge amounts of process data in many databases at many locations but were limited in how they could use it to produce actionable information to improve operations, drive down costs and increase efficiencies. How could they increase the operational value of all that data? Lloyd Colegrove, Director of Fundamental Problem Solving, discussed how Dow unlocked the value of the data with an innovative new approach to enterprise manufacturing intelligence (EMI) that uses their existing infrastructure and is within reach of almost every manufacturer today. Managing a multinational chemical firm and its supply chain requires every bit of decision support management can muster, but to quote ARC, “Everyone is drowning in data, but starving for information”. In their studies ARC identified the top three wish list for manufacturing software solutions: • Analytics – the key to creating actionable intelligence; • Collaboration – the means to leverage collective knowledge; • Cloud – finding the most efficient way to distribute real-time information. These all point to Enterprise Manufacturing Intelligence as the realistic means for manufacturers to control and optimize their processes and improve corporate management. To reach the EMI goal, Dow faced the complex data problems common to every manufacturer – multiple generations of data systems from multiple vendors each in its own silo and no direct way to consolidate and analyze the data to support comprehensive process management. During this conversation, Mr. Colegrove will open the Dow EMI playbook to present a real-world approach to EMI that any manufacturer can apply to the process data collected in historians, LIMS, MES or other process databases. Our Guest – Lloyd Colegrove, Fundamental Problem Solving Director, Dow Chemical. Mr. Colegrove is a 23 year veteran of chemical production. From R&D to process optimization, he has led the successful effort at Dow to integrate process data and implement scalable EMI. View Recording - http://bit.ly/17yjGOn

1. Manufacturing Intelligence for Intelligent Manufacturing™
May 15, 2013
A Conversation:
Maximizing the Value
of Process Data

2. Manufacturers are drowning in data,
but starving for information.
ARC, 2012
The next level of productivity gains
in manufacturing must be achieved
through EMI. IDC, 2011

3. Lloyd Colegrove
Dir. Fundamental Problem Solving
Dow Chemical
Louis Halvorsen
CTO
Northwest Analytics
Our Guests

4. Problem: Discrete Data Usage
• No plan
• We work, data sits
Manufacturing
Products
Monitor
Safety
Product
Release
Process Control
Data Data Data

5. From Very Big Data to Knowledge
Analyze
Report
Prepare/
Distribute
Capture
Data
Aggregation
Analyze
Report
Capture
V
A
L
U
E
Data Sources
Data Connectivity and
Integration
Analytics and Notification
Dashboard, Graphics, and
Reporting
Collective Knowledge
Collaboration

6. Future Workflow – as dreamt on a paper napkin
Retrieve
Data
Analyze
Data
Join
Data
Quality
Analyst
A
Wonderful
tool
SIMCA-P
Matlab
“Services Layer”
This services Layer will
know how to interact with
all the different databases
(1) Discover what is available
& show it to the user
(2) Retrieve data once user
says what s/he wants
Manually or unattended.
Join data depending
on goals:
• Continuous
• Batch
• Multiple plants
What the User Sees: A Workflow Implementation Tool
Pirouette
Etc.

7. Challenges
• Data available in
– instrument software
– Lab information systems
– process historians
– SAP-like product systems
• Data collected at different time intervals
– Indexed differently; some in time, some in
batchID
• Data integrity impacted by e.g.
– Natural plant variation
– Inappropriate plant operation
– Vagaries of chemical processes (reaction
kinetics, etc.)

8. Solution of Choice – NWA Focus EMI®
• Core EMI Services
– Direct data-source connectivity
– Real-time data aggregation
– Comprehensive analytics
– Role-based dashboards
– Alarm & notification
• “Accelerating” Services
– KnowledgeBase
– Collaboration

9. NWA Focus EMI® Multi-plant Implementation
Plant #2Plant #1 Plant #3 Plant #4
LIMS
MES
Hist
Off-line SPC
Real-time Dashboards
Off-line SPC
Real-time Dashboards
Off-line SPC
Real-time Dashboards
Off-line SPC
Real-time Dashboards
LIMS
MES
Hist
LIMS
MES
Hist
LIMS
MES
Hist
Corporate:
- Management
- Production
- Engineering
- Quality
Enterprise
Systems
Northwest Analytics Confidential
NWA Focus EMI® Enterprise Deployment
NWA Focus EMI® Collaboration
NWA Focus EMI® KnowledgeBase

10. How is NWA Focus EMI® Unique?
• Direct data source connections –
no data replication
• Ubiquitous analytics layer –
meaningful information, not
simply data
• Accelerated EMI
• KnowledgeBase
• Collaboration
• Implementations

11. NWA Focus EMI®
Demonstration

12. ROI, Benefits Discussion

13. Thanks for joining us!
For more information about
NWA Focus EMI®, contact
Northwest Analytics at
nwa@nwasoft.com
or 888.692.7638

14. Manufacturing Intelligence for Intelligent
Manufacturing.™
Link to recorded webinar

15. 0 20 40 60 80 100 120 140 160 180
Laggard Manufacturer
Sophisticated Manufacturer
With NWA Focus
Identify Problem
Gather data
Compile Report
Analyze/Problem
Solve
NWA Focus EMI® Benefits
Time is money
7 hrs
168 hrs
88 hrs

16. NWA Focus EMI® Payback & ROI
Solution payback average: 2-6 months
• Payback & ROI Factors
• Recalls
• Waste
• Reporting cost/time
• Risk reduction
• Information Lag
• Data Inaccuracy
$0 $500,000 $1,000,000 $1,500,000
Reporting
Waste
Minor Recall
Cost/Issue

17. Lloyd Colegrove,
Dir. Fundamental Problem Solving
The Dow Chemical Company
lfcolegrove@dow.com
979.238.9948