Material tracking and mass balancing in Chocolate Manufacturing Stefan la Grange (AMR Automations)...
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Transcript of Material tracking and mass balancing in Chocolate Manufacturing Stefan la Grange (AMR Automations)...
The Magical World of Chocolate Manufacture
Material tracking and mass balancing in Chocolate Manufacturing
Stefan la Grange (AMR Automations)Fiona Byrns (for Orley Foods)
Agenda
Introduction
Project Solution
Benefits
Considerations
Summary
Mixing
•Cocoa Butter or Equivalent•Sugar or SweetenersGrin
ding
•Cocoa Mass or Powder•Emulsifiers•Powdered Milk
Liquefaction
Chocolate manufacture
Pressure and Temperature measurement
Project Scope
Orley Foods Manufacturing
Raw Material Receiving
Chocolate Manufacture
Fat Supply
Fat Melters
Storage
Tanks
Heat Exchangers
Mixing
Conches/
Grinding
Storage &
forming
Sugar Manufacture Finished Goods
Background to the Project
► Seamless and transparent integration throughout the Company manufacturing systems and business system
► Manufacturing system designed for expandability, ease of integration and contextuality.
► Information that is important, relevant and contextual to be published to a portal for easy access
► Ability to trend and trace process issues and speed up trouble shooting.
Project Goals
► Traceability of fat usage and additions against works orders
► Monitoring / logging of process parameters► ERP integration to Syspro► Overall system upgraded to latest technologies
▪ Network▪ Windows / SQL Server environment▪ SCADA system▪ PLC system
► Ingredient management of recipes► Introduction of expandable reporting
infrastructure
Agenda
Introduction
Project Solution
Benefits
Considerations
Summary
Tender process
► Requirements of integrator and solution▪ Cape Town presence▪ Instrumentation, PLC, SCADA and database
development experience▪ Previous experience in food and beverage
industry► Several solutions investigated
▪ Siemens▪ Rockwell▪ Citect
Why Wonderware
► Proven functionality in the Food and Beverage industries
► Proven integration into business systems (SQL database)
► Well supported, widely used nationally and internationally
► Several solution providers / system integrators▪ Development into the future▪ Increased availability of resources (call-outs)
Project Design
► Functional specification prepared
► Detailed design process▪ Network topology
▪ PC/Server infrastructure
▪ PLC infrastructure
▪ Data flow
Project Description
► Develop ArchestrA model▪ S95 standard▪ Model includes future upgrades
► Use model to define data capturing points for EOM
Topology
EOM
Project Design
► Design Intouch SCADA▪ Dual display
► AMR’s first project with ArchestrA 3.0 and Intouch 10.0
► Converted AMR’s standard valve/motor SmartSymbols to ArchestrA graphics
Project Design
Project Description
Project Description
ERP Integration / WO Management
► ERP integration to Syspro via holding database▪ WO’s pushed down from Syspro indicating
• Raw material, tank and equipment allocation/scheduling
► Operators start and complete WO’s SCADA
Syspro serverWonderware
Historian
Intouch SCADA
ERP Integration / WO Management
► Example of WO Management at SCADA level
ERP Integration / WO Management
Project Description
Project Description
WO – Modify execution time
WO – Re-allocate
WO – Remove from plan
PLC
► Allen-Bradley Compact Logix
► Beckhoff Ethernet/IP remote I/O units
► Program designed with complete process control management in mind (for future phases)▪ Manufacturing instructions
▪ Process parameters (Mixing times, pressure and temperature checks and operator prompts)
▪ Fat transfer route allocation
► Current program only handles fat transfer route allocation
Reporting
► Wonderware Information Server
► MS-SQL Reporting services
Reporting
Reporting
Reporting
Agenda
Introduction
Project Solution
Benefits
Considerations
Summary
Benefits / Goals Achieved
► Batch size consistency▪ No need for extensive additions to correct
recipe failures► Raw material allocations tracked
▪ What fat goes where► Better process control tracking
▪ Alarming at SCADA level▪ Trouble-shooting (temperatures, pressure,
grinding times)▪ Operators
Benefits / Goals Achieved
► Significant savings in fat usage► Batch processing times where standardized
▪ Less usage of resources i.e. power► Minimised batch/formulation corrections
▪ Savings in additional raw materials to batches.
Agenda
Introduction
Project Solution
Benefits
Considerations
Summary
Lessons Learned (PLC)
► User defined data structure always good (duplication of devices similar control)
► I/O server integration with tagnames instead of address reference
► Ethernet/IP needs managed switches to handle IGMP Snooping (Internet Group Management Protocol)
Lessons Learned (Wonderware)
► Domain Security▪ Tighter control with existing business system and
network policies▪ Client responsible for user manager/rights (IT
department)
Lessons Learned
► Understanding scope and planning vital▪ Previous projects failures overcome▪ Plant downtime was managed
► Plant process visibility greatly improved▪ Updated P&ID▪ Operations / process flow
► Increased speed of data availability
Agenda
Introduction
Project Solution
Benefits
Considerations
Summary
Project summary / conclusions
► Phase I successfully completed by AMR using Wonderware technology▪ Increased process control and shop floor visibility
► Phase II will further utilize the solution into other areas of the plant
► Future phases will allow for data to be written back to Syspro▪ Automatically closing works orders
Thank you