Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.
PUBLIC INFORMATION
Name - Arial Narrow 16pts
Title - Arial Narrow 16pts
Date - Arial Narrow 16pts
Rockwell Automation TechED 2015 @ROKTechED #ROKTechED
Southwest Baking Improves Flexibility, Reduces Costs with FactoryTalk Batch
Robert Wroblewski
Plant Engineer
Randy Otto
Systems Integrator
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved. RA-TechED 2015 @RA-TechED #RA-TechED
Agenda
Control Software Upgrade
Batch System Upgrade
Solution and Results
Challenges
Southwest Baking, History
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved. RA-TechED 2015 @RA-TechED #RA-TechED
Southwest Baking LLC.
3
High Speed Production Facility
Operating at 85-90% Capacity with a Skeleton Crew
Have no room for downtime or inefficiency in our process
OEM Batching system in place
Did it work?
It ran, reported
Reliable? Accessible? Efficient?
History:
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved. RA-TechED 2015 @RA-TechED #RA-TechED
Southwest Baking LLC.
4
Limited Flexibility and Accessibility
Solely Based on Ladder Logic
Tied to ridged programming constraints
Had no access to system to repair
Data Collection and reporting
Industry is changing,
We needed accurate, usable reports – now, not tomorrow, not the next day!
Challenges with OEM
We Needed a workable, reliable, stable, expandable System
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved. RA-TechED 2015 @RA-TechED #RA-TechED 5
Southwest Baking LLC
Needed to replace our limited system
Looked at other Solutions
OEM Software, Other generic solutions
Contacted our Rockwell Automation
FactoryTalk® Batch Demonstration of the PlantPAx® concept
Offered the Flexibility, Data Collection, Accessibility
Learned about the S88 Programming Standard
Added the Ability to be more adaptable to the customer, through its Modularity
Worked with ECS Solutions
FactoryTalk Batch was the Solution
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved. RA-TechED 2015 @RA-TechED #RA-TechED 6
Southwest Baking LLC
Reduced Draw time: possible tor run at Maximum Capacity
Changes Recipes, ingredient orders without major program changes
Modularity – allows us to keep up with Customer needs quickly and reduced cost
Delivery accuracy – making Nutritional panel possible for each batch we run
Data collection, Reporting – reliable, accurate, we have years of usable data
ROI – Financial return,
Best ROI is Doing what is right for the customer, associates and the future
Results
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved. RA-TechED 2015 @RA-TechED #RA-TechED
Agenda
Control Software Upgrade
Batch System Upgrade
Solution and Results
Challenges
Southwest Baking, History
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved. RA-TechED 2015 @RA-TechED #RA-TechED
Control and Information Solutions for Industry
8
Founded in
1977
Evansville, Indiana
15,000 SF
building, with
panel shop
specializing in:
Batch and Batch/Continuous Process Control Solutions
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved. RA-TechED 2015 @RA-TechED #RA-TechED
From ECS’s Perspective
ECS was contacted to investigate the need to replace the batch
system
Objective: Existing batch system was obsolete and operating on a
failing computer
6/2/20
15
9
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved. RA-TechED 2015 @RA-TechED #RA-TechED
Batch System Upgrade: DEFINE
10
LISTEN
EVALUATE
VALUE-FOCUS
JUSTIFY
Obsolete batch computer and software
Can existing control software be reused
Campaign Mgmt, Material Mgmt, Reporting
Single instance of a batch computer failure costs
more than this project
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved. RA-TechED 2015 @RA-TechED #RA-TechED
ControlLogix®
Pro
ced
ura
l
Co
ntr
ol
Recipe
Management
System
Operator
Control
Batch System Upgrade: DELIVER
11
FactoryTalk® View SE
VALUE-FOCUS
• Campaign Management
• Material Management
• Reporting
Batch
Management
System
INTERFACE
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved. RA-TechED 2015 @RA-TechED #RA-TechED
Batch System Upgrade: RESULTS
20% cycle time savings
Reduction in downtime (average of 4 hours/event -> 1 hour/event)
Code was clumsy and difficult…
Equipment was not separated from the procedure
PLC program was not in small manageable blocks
making modifications to batch procedures required making changes to PLC code
HMI was not integrated very well with batch
6/2/20
15
12
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved. RA-TechED 2015 @RA-TechED #RA-TechED
Control Software Upgrade: DEFINE
13
LISTEN
EVALUATE
VALUE-FOCUS
JUSTIFY
Limited flexibility
Feasible based on previous experience, results
Enable the operator, accuracy/consistency
Flexibility would pay for itself in 1 year
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved. RA-TechED 2015 @RA-TechED #RA-TechED
ControlLogix
Pro
ced
ura
l
Co
ntr
ol
Operator
Control
Control Software Upgrade: DELIVER
14
Batch
Management
System
NEW CONTROLLER
PROGRAM
VALUE-FOCUS
• System Flexibility / Agility
• Enabling the Operator
• Accuracy
FactoryTalk View SE
NEW HMI
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved. RA-TechED 2015 @RA-TechED #RA-TechED
Control Software Upgrade: RESULTS
22% reduction in cycle time
Accurate delivery of ingredients
Reduction in downtime (average of 1 hour/event -> 3 minutes/event)
6/2/20
15
16
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved. RA-TechED 2015 @RA-TechED #RA-TechED
CONCLUSION
Applying the ISA-88 Standard “the right way” increases value
Changing software only can achieve results
Look for high value savings, they exist in all process systems,
sometimes with little cost
6/2/20
15
17
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved. RA-TechED 2015 @RA-TechED #RA-TechED
Please take a couple minutes to complete a quick session survey to tell us how we’re doing. On the mobile app:
1. Locate session using Schedule or Agenda Builder.
2. Click on the thumbs up icon on the lower right
corner of the session detail
3. Complete survey
4. Click the Submit Form button
Thank you!!
3
1
2
4
We care what you think!
Top Related