An analysis model or process model is an individual, model like calculation tool that can calculate single processes or many processes that are linked to each other. There are various ways of using such a model for optimisation of costs and plant operation. It also supplies a very good overview of how the internal and external processes are linked to each other. With analysis models production plans get calculatable and therefore analysable.
The analysis models of ING-ON for example can be used for multi-feed-plants to calculate needs, product properties and costs related to the raw materials used. This enables to assess and analyse the efficiency of a plant while taking the effects of different raw material in the production process into account. Effects of raw material can be the need of additives, higher/lower maintenance or reduction of process quality (especially in chemical processes). A model consists of mathematically, to the processes related models and real production and plant data. As a result the plant and its processes can be analysed and characterised with indicators (e.g. €/MWh, energy efficiency etc.) related to the properties of the used raw material. This allows an economic and foresight planning of the plant supply and production, adjusted to the plant properties. An analysis model enables the continuously tracing and calculation of profit/loss and payout time for investments.
By using an analysis model it is possible to analyse and optimise the raw material purchasing, plant operation and plant efficiency for different raw materials. The development of the model is executed by ING-ON on site and in our IT-Laboratory. We build an interconnected mathematic model from the plants core processes that afterwards is ready to be used for analyses and calculation. Additionally we evaluate the model and add Input/Output-functionalities, so that it can be used permanently and also be updated or adjusted. The supply of fresh production data can be realised with interfaces to third-party software, existing software or any of our developed database applications. Missing software can be developed from ING-ON.
Because of the possibility to picture the plant efficiency in indicators and plan the production foresightly according to specific raw materials, an analysis model is an import help for decision-making in terms of successive optimisation of the plant over time.
Our services in the field analysis models are:
- Analysis and assessment of all plant processes in term of costs, needs, criticality for production and influence parameters
- Creation of a model of all relevant processes in their technical context (flow charts, connections of influence parameters)
- Build-up of mathematical models to calculate the processes and the plant production
- Linking of the model with databases for continuously supply with production data or adding data input possibilities for manual supply
- Programming of analysis- and assessment-tools to enable a usage of the model in planning of plant operation and supply
- Analysis of the optimisation potential by evaluation of the model
- Documentation of the model
- Integration of the model in the work flow and consulting
Benefits of an Analysis Model:
- It’s possible to archieve economic benefits in plant operation, that are easy to carry out because of indicators and decisions helping features based on the plant processes
- Foresight planning of raw material supply, process material and their costs based on the production goals of the plant:
- Transparent cost structure:
Needs and costs for the achivement of the production goals, in respect of the market situation, can be pre-calculated by using an analysis model. The complete cost structure of a plant is calculated in detail and linked to each other, in respect to all processes.
- Strategical raw material supply:
Beneficial and low cost raw materials, in respect to the whole production process, can be identified on the market before they are purchased. With the integrated analysis-tool both prize and production costs are taken into account for calculation of a good raw material.
- Optimisation of product quality: An analysis model enables the pre-calculation of the product quality based on raw material properties.
- The complex situation of having a lot of interconnected processes and tons of data is simplified in an analysis model:
Process models help to picture the complex and interconnected plant and operation processes in a simplified and understandable way. This helps to gain knowledge about the own production processes and efficient optimisation.
- Monitoring of plant processes:
Current and historical information of the plant operation enables monitoring, controlling and influencing internal processes based on indicator and graphical analysis.