10% Increase in Production Capacity
Bayer engineers use TrendMiner to improve performance
Whipped cream might sound like a delight, but that’s not the case when the material in a chemical reactor looks and acts like it. Bayer engineers at one of its Crop Science plants struggled with a sticky mass that resembled the popular dessert topping when it added starting material to one of its reactors. Instead of processing as it should, the material changed into a viscous phase.
“When you have this effect, you can add the remaining amount of the starting material only very slowly and, at the end of the day, this reduces production output,” said Marita Beyer-Weitkus, Bayer’s plant manager in Dormagen, Germany. “Using a reporting system that checks overall equipment efficiency, it was possible to identify the process step where the delays occurred. Then, using TrendMiner, a deeper analysis of this process step was carried out, and the reason for the problem was found.”
Like many chemical companies that chose to embrace Industry 4.0 technology during the COVID-19 pandemic, Bayer sought a way to democratize operational data to remote workers across the globe. The company launched TrendMiner as a pilot with specific use cases in mind at two of its sites. The trials were successful, and Bayer moved ahead with deployment.
So far, adoption has proven to be successful.
“We try to keep the threshold to start TrendMiner as low as possible,” said Bodo Güldenring, who is the TrendMiner Program Lead at Bayer. “We do that through a centrally sponsored program to minimize administrative work and index the data before the initial trainings start.”
Bayer deployed TrendMiner in an AWS cloud environment that collected local, regional, and centralized process data from various historians. Then, the company formed a team of its engineers, data scientists, and IT experts to develop a standard implementation process.
Bayer engineers have achieved many benefits using TrendMiner. Among them are:
Quickly find the root cause of process anomalies
Share knowledge about process behavior and solutions across sites
Establish a cloud-based advanced industrial analytics solution that provided greater access to data
Realize a 10% increase in production capacity
Improve collaboration among process experts and central data teams
If you ask Bayer AG engineers about their digitalization journey, they will tell you it is gaining speed. Their commitment and dedication to improving their analytics maturity level has earned the life-science company the 2022 TrendMiner of the Year Award.
Bayer started its journey into process data analytics two years ago. The company did an extensive evaluation of solutions that could help them improve its operations. Bayer chose TrendMiner because of its unique selling proposition of putting software users first.