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Capacity & Product Mix Management

Capacity & Product Mix Management is one of Pavilion's newest developments in the field of Predictive-EMI (Enterprise Manufacturing Intelligence). Leveraging the process models that are part of Pavilion's MPC Industry Solutions, Capacity & Product Mix Management presents a real-time, dynamic comparative of the plant's theoretical capacity and its current production rate. The objective is to provide timely visibility into potential capacity from existing assets, thus avoiding latency of decisions.

The application performs dynamic constraint profiling based on current and predicted operating conditions, displaying a profile of the constraints associated with each product. By linking into the corporate business system, the application automatically quantifies the potential gain of increased capacity as a result of driving production up to the prevailing constraints.

Capture opportunities to optimize capacity as these become available

Today, production analysis is typically based on historical data and user-defined spreadsheets. In some cases, data mining tools are employed in conjunction with real-time or near-real time data from the control infrastructure, yet this technique is inherently retrospective and its value is limited to understanding what happened.

By leveraging Pavilion's strength in predictive technologies, and integrating financial variables with a proxy of the high-fidelity model that is controlling the process, users can understand the economic value of opportunities as these unfold, and then capture profitable opportunities or shed non-profitable opportunities proactively and with a greater degree of confidence.

Quantify the lost opportunities associated with key production constraints

Production facilities make significant investments in capital improvement projects, aiming to streamline production and de-bottlenecking manufacturing units using anecdotal evidence based on a plant's historical performance. Often, a major capital asset is replaced with the expectation that the removal of this prevailing constraint will result in production improvements, only to learn that the achieved improvement is minimal because the available capacity to the next constraint is miniscule.

Pavilion's Capacity Management application automatically calculates a facility's top 5 constraints and quantifies the latent capacity available across these constraints, providing operations management with a financial profile of production opportunities restricted by these prevailing constraints. In aggregate, the application allows for capital expenditure planning with a greater degree of confidence, having a thorough understanding of the potential economic improvements associated with de-bottlenecking projects.

Economic Energy Optimization

Economic Energy Optimization is one of Pavilion's newest developments in the field of Predictive-EMI (Enterprise Manufacturing Intelligence). Leveraging Pavilion's patented Hybrid Modeling Framework and powerful predictive capabilities, the Economic Energy Optimization application consists of multiple sub-models of production, utilities, and emissions integrated with the client's financial system to present an economic optimum that meets a facility's predicted energy demand.

Creating an integrated Energy-Supply model

Incorporating the variable costs from a client's business system, economic sub-models are built for each energy-generating asset at a facility to determine each asset's financial profile, taking into account their generating capacity, efficiency curves, and operating costs. Each of these asset sub-models are combined to create a plant's holistic Energy-Supply model.