The production in the chemical industry is characterized by process-oriented and continuity, relying on precise formulations and advanced instrumentation for process control. The production involves various reaction equipment, such as reactors and distillation columns, used to carry out complex chemical reactions and material separations. The entire process needs to be strictly monitored to ensure product quality and production safety, while optimizing energy use and reducing environmental impact. A-MES includes the following functionalities in the chemical industry:
1.Production Planning Management
The core of the manufacturing system is production planning management, which allows companies to develop, adjust, and optimize production plans based on market demand, raw material supply, and production capacity. This helps to improve production efficiency, reduce inventory costs, and ensure timely delivery.
2. Operation Management
The system provides detailed operational guidance and real-time monitoring to ensure that operators perform production tasks in accordance with established process parameters and steps. This helps to maintain product quality and production efficiency while reducing operational errors.
3.EMS Energy Management System
The manufacturing system in the chemical industry, through an integrated Energy Management System (EMS), achieves comprehensive monitoring and optimization of energy consumption. EMS can track and analyze various energy usages, such as electricity, water, heat, steam, etc., to identify opportunities for energy saving and emission reduction. EMS helps chemical companies reduce energy costs and promote sustainable development.
4.HSE Health, Safety, and Environmental Management System
The HSE management system focuses on health, safety, and environmental protection to ensure that production activities comply with relevant laws, regulations, and corporate standards. The system manages and mitigates safety risks in the production process through risk assessment, accident prevention, and emergency response plans.
5. Quality Management
Quality management in the chemical industry primarily adheres to national laws, regulations, and relevant chemical product standards, including national, industry, and local standards. A-MES is deeply integrated with these standards, enabling companies to grasp changes in national and industry standards in real-time, reducing unnecessary losses. It also provides full lifecycle traceability for products.
6.SIS System (Safety Instrumented System)
SIS is a key safety layer in the manufacturing system, ensuring the safe operation of critical production processes through independent control logic and equipment. SIS can automatically take control actions, such as shutdown or switching to a safe state, when a potential hazard is detected.
7. Plant Inspection
The system supports regular and condition-based plant inspection sampling, improving inspection efficiency and accuracy with mobile devices and automated tools, and promptly identifying potential issues such as leaks.
8. Equipment Management
Equipment management functions include preventive maintenance, fault diagnosis, performance monitoring, and asset tracking. This helps to reduce equipment failures, extend equipment life, and improve Overall Equipment Efficiency (OEE).
9. Equipment Integration and Data Collection
The manufacturing system is closely integrated with various production equipment and sensors, enabling real-time data collection and analysis. This data is crucial for production monitoring, quality control, and equipment management.
10.CCR Central Monitoring
The Central Control Room (CCR) serves as the nerve center of the manufacturing system, providing centralized monitoring and control functions. It can monitor the production process in real-time, respond quickly to production anomalies, and ensure production continuity and product quality.
11.Software Integration
The A-MES system is integrated with other enterprise management software such as ERP, WMS, LIMS, etc., to achieve data sharing and business collaboration. This integration improves the efficiency and accuracy of the information flow, supporting decision-making across departments.
12. Integration of Hardware and Software
The system is closely integrated with hardware devices, such as sensors, controllers, actuators, etc., and the software platform, forming a unified automated and informatized production environment. The integration of hardware and software enhances the system's reliability and flexibility, making the production process smarter and more efficient.
Customer Cases
