A journey from Manual Control

Transcription

1 Innovative Control, Inc. 456 S. Dartmoor Drive Crystal Lake Illinois (815) FAX (815) A journey from Manual Control Name Dave Stock Title Whitmore s journey from manual Date March 25/25,

2 Agenda The Call The Vision The Tasks The Outcome Future Plans 2

3 The Call Manager Experienced with the reward of automation Dave, (small talk) I need your help. You know what I want and when can you be here to start a plan. The site visit and the world of lubricants. 3

4 The Call The Site Visit Existing Charging Infrastructure Volumetric Meters Operator Setup Scales on Tanks PLCs & HMIs No Plan No Documentation Never Commissioned Reliability & FRC were a challange 4

5 Agenda The Call The Vision The Tasks The Outcome Future Plans 5

6 The Vision - Automation Automated Bulk Charging Was yet to be designed Temperature Control Some single loop systems were in place Agitator Control Existing VFDs Recipe Driven Process Finding the right people to get on the bus Data/information 6

7 The Vision Controls Control Logix Distributed I/O Comm. Bus to devices Operator Interface Low Maintenance Local to operators Bar Code reader capable Batching/Recipe Training Electrical Reliability Motor Control out of the process area System Documentation Data Collection Historian Web Reporting Material Consumption ERP Integration JD Edwards 7

8 Agenda The Call The Vision The Tasks The Outcome Future Plans 8

9 The Tasks Infrastructure Motor control Vision to Execution Point to point wiring would become DeviceNet VFDs would go to EthernetIP from using the keypad on the VFD Valve Control Existing actuators would be moved to Point I/O New actuators would utilize ASi Bus Existing Panels would be utilized + New ones Added panel Mount PCs (RDP) Added I/O modules Mass Flow Meters EthernetIP Minimal MFG Interruption Front End Design 9

10 The Tasks Vision to Execution Operations FT ViewSE Operating on a virtual server 15 RD terminal server in a virtual server Remote access for engineering and management Process Objects FT Batch FT historian 500 tag license FT Transaction Mgr Material consumption FT Vantage Point Web Server is a virtual server Control Control Logix Phase Logic to support the FTBatch Process blocks & add-on instructions EthernetIP for DeviceNet, Asi Bus, Mass Flow Meters FT Batch Equipment Model Procedures Recipes Material Consumption! 10

11 The Tasks Electrical & Mechanical 230 Valves (2 and 3-way) 3 IntelliCenter Sections (30 ) 10 Control panels with Point I/O and FTView Client 1 Network Rack & Switch 1 Main Control Panel Control Logix Mass Flow Meter Comms ASI Bus Gateways New Electrical Service Removal of pump pit outside Relocate Servers to IT space Cost of Installation 11

12 Agenda The Call The Vision The Tasks The Outcome Future Plans 12

13 The Outcome Automated Charging Computer controlled Mass meters accurate to 0.1% of flow rate Closed system from tank to mixer Automatic, timed nitrogen purge Benefits: Reduces production time Reduces costs Eliminates cross contamination Consistent product Better Housekeeping Documented actions

14 The Outcome Computer-Driven Batch Manufacturing Every formula procedure and component quantities are programmed by engineers and processed by computers

15 The Outcome Batch Historian Tracks key variables Temperature Agitator Weights Time Valve Set points Benefits: Statistical Process Capabilities Multi batch reviews simultaneously Root Cause Analysis

16 The Outcome Product variation has been significantly reduced Cycle time for Lithium based greases have been reduced by average of 30% Reduced costs Greater production capacity Reduced human error More uptime

17 The Outcome Before After % Improvement Time 32 hrs 23 hrs 28 % Penetration 0 strokes std dev 17.3 mm 9.5 mm 45 % Penetration 0 strokes variance Penetration 60 strokes std dev Penetration 60 strokes variance 299 mm 91 mm 70 % 13.6 mm 10 mm 26 % 184 mm 101 mm 45% 9 hour average cycle time reduction 150 additional batches of capacity in Lithium Cell 2,350,000 # s of additional production 28 % increase in capacity

18 Agenda The Call The Vision The Tasks The Outcome Future Plans 18

19 Future Plans Additional Capacity More Process vessels to be integrated into the system ERP Connectivity Mfg Planning Work in Process tracking Material Consumption Customer Service visibility OEE Traceability 19

20 Innovative Control, Inc. 456 S. Dartmoor Drive Crystal Lake Illinois (815) FAX (815) Lessons & Questions Big Vision Plan - Bite Size Execution