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Leading Chemical Company

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Client The organization is recognized for its large-scale production capabilities, advanced infrastructure, and commitment to

Client

The organization is recognized for its large-scale production capabilities, advanced infrastructure, and commitment to innovation and operational excellence. It collaborates with international partners to drive efficiency, safety, and sustainability across its industrial operations.

 Solution Provided

We provided ongoing support and enhancement services for Client’s Manufacturing Operations Management (MOM) i.e. 

1)Operation and Comprehensive Management (OCM) domain applications

2)Reliability, Integrity and Integration Management (RIM) domain applications

3)Inventory and Quality Management (IQM) domain applications

This includes:

  • End-to-end support for MES manufacturing operations.
  • System monitoring, issue resolution, code enhancements, and change request coordination.
  • Proactive vulnerability mitigation, patch management, and security hardening.
  • Routine maintenance and performance optimization to ensure high system availability and reliability.

 Technology

OCM

  • OPD is a centralized, web-based platform designed to support various environments and functions essential for plant operations, serves as a single repository for value-added tasks performed by workgroups, streamlining operational workflows.
  • Aspen InfoPlus.21 ® holds process related data measured value read from plant IPCS, set-point value read from or to be written to a IPCS and value representing the result of a calculation internal or external to InfoPlus.21 
  • Aspen Process Explorer is a container for a variety of displays and tools, to display and manipulate data in real-time from a database server such as Aspen InfoPlus.21 

RIM

  • Microsoft BizTalk Server for Integrating different applications with guaranteed delivery of messages to ensure no loss of data in any case.
  • Oracle Primavera P6 for plan, manage and control large scale projects across industries. It helps in scheduling tasks, allocating resources, tracking progress and ensuring timely project delivery.
  • eSOMS Suite Mobile Operator Rounds application is the solution for plant operations management data 
    collection and analysis needs in a mobile environment integrated with OPD (Operations Dashboard) for smooth operations.
  • Asset Performance Management (APM) software is a powerful digital solution designed to help industrial organizations—especially in the energy sector—optimize the performance, reliability, and safety of their assets.

IQM

  • ABB TMAC Plus MES integrated with ABB 800xA DCS, Aspen IP.21, SAP, and SQL Server for real-time control, data logging, ERP synchronization, and inventory reconciliation.
  • LIMS (Laboratory Information Management System) for sample collection, test execution, result reporting, and performance analysis.
  • EPKG (Elastomers Packaging System) for managing packaging operations of raw, semi-finished, and finished products.

Impact

  • MES Stability: Achieved high availability and performance for all applications through proactive monitoring and 24/7 coordinated support.
  • Redesigned application based on user feedback, resulting in user satisfaction. Added new features aligned with user needs, improving engagement and retention.
  • Upgrade:
    • Successfully Upgraded to BizTalk 2020 from BizTalk2013r2 without vendor support, this will add security enhanced by having TLS 1.2 and new features are now available to make process more efficient. It also has the more options for Hybrid model Integration.
    • Successfully upgraded the WebLogic 12.2.1.3 to 12.2.1.4, this will add security enhancements, bug fixes, improved stability and performance.
    • Application servers migrated to latest supported Windows OS version. Database servers migrated to latest supported SQL server, from shared instance to standalone instance, host.
    • Upgrade successfully completed for eSOMS application to V6.3.17 from V6.1, this will resolve the PED sync issue and enables server migration to latest OS and DB.
  • Inventory Precision: Ensured to update passwords for the service accounts in required areas related to Application. Enabled real-time reconciliation across Planning, Scheduling, ERP, and LIMS systems, reducing manual errors and enhancing data integrity.
  • Operational Continuity: Enabled SCOM monitoring for all applications in Prod, this process will create an alert through monitoring team if there is any error logged in the dashboard. Enhanced uptime and reduced delays through close collaboration with DCS and infrastructure teams and regular system and application upgrades.
  • Security Compliance: Implemented HTTPS, and enabled TLS1.2 protocol and regular patching to align with cybersecurity best practices.
  • Vulnerability Reduction: Achieved up to 90% reduction in vulnerabilities through targeted updates and configuration hardening.
  • Legacy Issue Resolution: Resolved a long-standing EDR agent penetration test vulnerability via BizTalk Upgrade and decommission of old servers in production. Improved the utilization of PED-eSOMS application by resolving critical issues related to synchronization of tours from PED devices, OPD integration issues.
  • Visibility & Control: BizTalk Admin console will provide monitoring and reporting through BHM with role-based access. Delivered centralized monitoring and reporting through SQL-based dashboards with role-based access.
  • Scalable Enhancements: Developed new integrations across TMAC, LIMS to support evolving operational requirements.

P6 Team Member implemented to view assigned tasks, update progress and report status. It helps streamline communication between project managers and team members.

Developed new custom Dashboards, Reports, Checklists and Inspections as per Business requirements in APM, resolved critical issues related to application performance, data issues with SAP. Developed a no of custom Data-loaders for manual Bulk updation/insertion of data into APM.

IP21 maintained seamless integration with DCS, LIMS, TMAC, Envision, and Elastomers Packaging systems to maximize uptime and ensure uninterrupted operations.

Implemented custom code changes to resolve bugs and enhance application performance and functionality, aligning with operational requirements in OPD.