Honeywell New Zealand Solutions Honeywell New Zealand Proprietary and Confidential Page 1 Honeywell...
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![Page 1: Honeywell New Zealand Solutions Honeywell New Zealand Proprietary and Confidential Page 1 Honeywell New Zealand Plant Automation Solutions Tom Lewis.](https://reader035.fdocuments.in/reader035/viewer/2022062515/56649cf95503460f949cac1b/html5/thumbnails/1.jpg)
Honeywell New Zealand Solutions
Honeywell New ZealandProprietary and ConfidentialPage 1
Honeywell New Zealand
Plant Automation Solutions
Tom Lewis
![Page 2: Honeywell New Zealand Solutions Honeywell New Zealand Proprietary and Confidential Page 1 Honeywell New Zealand Plant Automation Solutions Tom Lewis.](https://reader035.fdocuments.in/reader035/viewer/2022062515/56649cf95503460f949cac1b/html5/thumbnails/2.jpg)
Honeywell New Zealand Solutions
Honeywell New ZealandProprietary and ConfidentialPage 2
Meadow Lea Foods - Food Solutions
Company: Meadow Lea Foods
Location: Auckland, New Zealand
Process: Manufacturing Margarine, Cooking Oils and processing Dairy Products
Needs: Improve Quality & Reduce ‘Human-Error’
Expand Recipe Selection
Automate Reports and provide complete component tracing to meet legislation
![Page 3: Honeywell New Zealand Solutions Honeywell New Zealand Proprietary and Confidential Page 1 Honeywell New Zealand Plant Automation Solutions Tom Lewis.](https://reader035.fdocuments.in/reader035/viewer/2022062515/56649cf95503460f949cac1b/html5/thumbnails/3.jpg)
Honeywell New Zealand Solutions
Honeywell New ZealandProprietary and ConfidentialPage 3
Meadow Lea Foods - Process
Process: Batch
Phase 1: Weigh & Blend
Phase 2: Transfer (holding tanks)
Phase 3: Column (recipe management)
Phase 4: Discharge
Detailed Batch History reports are created during each Phase.
The final product quality and audit report is created at the Discharge phase.
![Page 4: Honeywell New Zealand Solutions Honeywell New Zealand Proprietary and Confidential Page 1 Honeywell New Zealand Plant Automation Solutions Tom Lewis.](https://reader035.fdocuments.in/reader035/viewer/2022062515/56649cf95503460f949cac1b/html5/thumbnails/4.jpg)
Honeywell New Zealand Solutions
Honeywell New ZealandProprietary and ConfidentialPage 4
Meadow Lea Foods - Automation
![Page 5: Honeywell New Zealand Solutions Honeywell New Zealand Proprietary and Confidential Page 1 Honeywell New Zealand Plant Automation Solutions Tom Lewis.](https://reader035.fdocuments.in/reader035/viewer/2022062515/56649cf95503460f949cac1b/html5/thumbnails/5.jpg)
Honeywell New Zealand Solutions
Honeywell New ZealandProprietary and ConfidentialPage 5
Meadow Lea - Flow Diagram
Product Orders Scheduling
Lab Recipe
Download
Weighing
& Blend
Transfer to Holding
Column
“Cooking”
Discharge
Auxiliary
Processes
Storage
or Packaging
Shipping &
Distribution
Recipe Calculation to Total Volume
(usually 10 tonne batches)
![Page 6: Honeywell New Zealand Solutions Honeywell New Zealand Proprietary and Confidential Page 1 Honeywell New Zealand Plant Automation Solutions Tom Lewis.](https://reader035.fdocuments.in/reader035/viewer/2022062515/56649cf95503460f949cac1b/html5/thumbnails/6.jpg)
Honeywell New Zealand Solutions
Honeywell New ZealandProprietary and ConfidentialPage 6
Meadow Lea Foods - Control Solution
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Honeywell New Zealand Solutions
Honeywell New ZealandProprietary and ConfidentialPage 7
Meadow Lea Foods - Blend Phase Detail
![Page 8: Honeywell New Zealand Solutions Honeywell New Zealand Proprietary and Confidential Page 1 Honeywell New Zealand Plant Automation Solutions Tom Lewis.](https://reader035.fdocuments.in/reader035/viewer/2022062515/56649cf95503460f949cac1b/html5/thumbnails/8.jpg)
Honeywell New Zealand Solutions
Honeywell New ZealandProprietary and ConfidentialPage 8
Meadow Lea Foods - Summary
• The Control System solution has been in operation for 7 years and keeps on expanding
• With the Batch solution, the consistency of recipe production, operator effectiveness, and quality reporting has improved by 100%
• The Batch User Interface means minimum training for Operators when introducing new recipes
• Batch History has provided essential data for Quality reporting, and meeting the strict demands of Food & Beverage Regulations in New Zealand
• The remote access function improved site support and reduced maintenance costs
![Page 9: Honeywell New Zealand Solutions Honeywell New Zealand Proprietary and Confidential Page 1 Honeywell New Zealand Plant Automation Solutions Tom Lewis.](https://reader035.fdocuments.in/reader035/viewer/2022062515/56649cf95503460f949cac1b/html5/thumbnails/9.jpg)
Honeywell New Zealand Solutions
Honeywell New ZealandProprietary and ConfidentialPage 9
Cavalier Bremworth - Carpet Solutions
Company: Cavalier Bremworth
Location: Auckland, New Zealand
Process: Manufacturing of high quality woolen carpet, mainly "Tufted" (stitched on a synthetic backing)
Needs: Improve Quality, Reduce Waste
Improve Efficiency
Identify Operating and Machine Problems (collection of statistical data for analysis)
![Page 10: Honeywell New Zealand Solutions Honeywell New Zealand Proprietary and Confidential Page 1 Honeywell New Zealand Plant Automation Solutions Tom Lewis.](https://reader035.fdocuments.in/reader035/viewer/2022062515/56649cf95503460f949cac1b/html5/thumbnails/10.jpg)
Honeywell New Zealand Solutions
Honeywell New ZealandProprietary and ConfidentialPage 10
Cavalier Bremworth - Process
Process: Continuous - Semi-Batch
Phase 1: Winding
Phase 2: Beaming
Phase 3: Tufting
Each phase is executed as a batch, and is tagged with an ID number, so quality tracking is possible.
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Honeywell New Zealand Solutions
Honeywell New ZealandProprietary and ConfidentialPage 11
Cavalier Bremworth - Winding
64 Winders spin the wool at 200kg / hour
The wool is unloaded and pre-treated
The wool arrives at the factory in large bales
Wool
Winders
![Page 12: Honeywell New Zealand Solutions Honeywell New Zealand Proprietary and Confidential Page 1 Honeywell New Zealand Plant Automation Solutions Tom Lewis.](https://reader035.fdocuments.in/reader035/viewer/2022062515/56649cf95503460f949cac1b/html5/thumbnails/12.jpg)
Honeywell New Zealand Solutions
Honeywell New ZealandProprietary and ConfidentialPage 12
Cavalier Bremworth - Beaming
From the winders, the wool is fed into the beaming machines.
1x Beam, holds about
500kg of wound wool.
200
Winder
“Cones”
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Honeywell New Zealand Solutions
Honeywell New ZealandProprietary and ConfidentialPage 13
Cavalier Bremworth - Tufting
From the beams, the wool is fed into the tufting machines, producing the finished carpet.
8 Beams
Tufting Machine
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Honeywell New Zealand Solutions
Honeywell New ZealandProprietary and ConfidentialPage 14
Cavalier Bremworth - Control Solution
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Honeywell New Zealand Solutions
Honeywell New ZealandProprietary and ConfidentialPage 15
Cavalier Bremworth - Batch Control
• Batches are specified from the Planning Department, and downloaded to the PlantScape system.
• Operators login before operating machines. The Batch ID is checked, and the operator productivity and machine efficiency is tracked.
• Each machine has a selection of “downtime” codes for tracking machine performance. Statistical data is reviewed to determine problem machines, and focus on reducing bottlenecks.
• Each machine has its own "Batch Control" program that is designed to guide the operator when starting/stopping batches.
• Each “Batch Control” program has logic steps and plant feedback to minimize error and maximize productivity.
![Page 16: Honeywell New Zealand Solutions Honeywell New Zealand Proprietary and Confidential Page 1 Honeywell New Zealand Plant Automation Solutions Tom Lewis.](https://reader035.fdocuments.in/reader035/viewer/2022062515/56649cf95503460f949cac1b/html5/thumbnails/16.jpg)
Honeywell New Zealand Solutions
Honeywell New ZealandProprietary and ConfidentialPage 16
Cavalier Bremworth - Carpet Solutions
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Honeywell New Zealand Solutions
Honeywell New ZealandProprietary and ConfidentialPage 17
Cavalier Bremworth - Carpet Solutions
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Honeywell New Zealand Solutions
Honeywell New ZealandProprietary and ConfidentialPage 18
Cavalier Bremworth - Summary
• The Control System solution has been in operation for nearly 6 years and keeps on expanding
• Cavalier Bremworth achieved excellent results:
– Reducing the number of operators and maintenance staff by 50%
– Increasing productivity by over 150% (by identifying machine downtime trends, focusing on Operator training, and providing operators with productivity information).
– This is a unique system, tailored for this application. But the principles can be applied to any industry.