Industry: Consumer Goods

Services and Materials Provided:

• Project management
• Distributed FactoryTalk ViewSE HMI system
• Redundant HMI servers
• Data collection system
• Microsoft SQL-based data storage
• Web-based reporting system: OEE (operational equipment effectiveness) reporting
  • Preventative maintenance reports on all robots and motors
  • Downtime reporting
• Reports tailored to specific users
• Ethernet network communications
• Network switches
• Industrial enclosures for plant floor computers

Situation Analysis

In conjunction with a new conveyor control system and robotic palletizing stations implemented by Applied Technologies, this customer needed a data collection and visualization solution for their entire plant.  The requirement was to cover all three buildings within their facility with a single system which would allow for control and report generation from anywhere within the facility given the proper user rights.

Technical Details

Applied Technologies designed, programmed, and installed a complete HMI and data collection system to meet this customer’s needs.  The system included a redundant HMI server setup to support their 24x7 operation as well as multiple clients in their various buildings.  Access to the system was limited by user login, so a user with sufficient privileges could access any part of the system from anywhere in the buildings.  New fiber optic and twisted pair media was run to support this functionality and to separate the control system traffic from the IT network.  Cisco switches were utilized for both server room and plant floor environments.  The data collection system gathered all pertinent data from the conveyor control system as well as the Applied Technologies provided robotic palletizing cells.  This allowed the customer to quickly pinpoint significant causes of downtime and even improve operator training.  It also simplified the management of production as the various department managers were able to quickly pinpoint key issues impacting performance and address the root cause quickly.  At a high level, the system gave them instant access to OEE (operational equipment effectiveness) measurements for the key pieces of equipment.