ap17: saint-gobain builds for the future with plantpax and production intelligence
DESCRIPTION
The production systems at a key Saint-Gobain facility, where high-tech fiber glass and construction materials are created, was at risk of obsolescence. With limited support and system expertise, maintenance and repairs were hard to sustain on the legacy process system. To remain competitive, the company turned to the PlantPAx process system with a production intelligence solution for increased productivity and reduced downtime. Utilizing FactoryTalk VantagePoint, View and Historian, the company now has access to a wealth of data for real-time trending and improved electronic data storage from three months to a year.TRANSCRIPT
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
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Saint-Gobain Builds for the Future with PlantPAxand Production Intelligence
Nick Thompson – Plant SuperintendentLarry Grate – Account Delivery Manager
AGENDA
Who is Saint-Gobain and PREMIER
Business Justification
Migration Strategy to PlantPAxTM
Leverage Production Intelligence
Solution
Results and Look Forward
Questions and Answers
WHO IS ADFORSSAINT-GOBAIN?
Nick Thompson
Plant Superintendent
ADFORS OVERVIEW
Saint-Gobain, the World Leader in sustainable habitat and construction markets, designs, manufactures and distributes BUILDING AND HIGH-PERFORMANCE MATERIALS, providing innovative solutions to the challenges of growth, energy eff iciency, and environmental protection.
Saint-Gobain manufactures the following materials: Flat Glass Ceramic Materials Abrasives Performance Plastics Saint-Gobain ADFORS
Exterior Wall Insulation (VERTEX) Wall Coverings (NOVELIO) Joint Tape (FibaTape) Bonded glass for thermal insulation and asphalt toppings (NewYorkWire,GlasGrid).
WHO IS PREMIER?
Larry Grate
Account Delivery Manager
PREMIER OVERVIEW
For more info . . .Visit PREMIER’s website at www.premier-system.com
Founded in 1991 Privately Owned 100+ Employees CSIA Certified (6 Years) Corporate Office Located in Smyrna, TN Regional Operations in S.E. U.S.
Smyrna, TN Decatur, AL Cincinnati, OH
PREMIER OVERVIEW
Rockwell Solution Partner Rockwell Control Solution Partner
Rockwell Information Solution Partner
Rockwell Process Solution Partner
Competencies PLC/DCS Programming and Configuration
HMI Development
MES Solutions
Legacy PLC/DCS Retrofits
Coordinated Drives Solutions
For more info . . .Visit PREMIER’s website at www.premier-system.com
Information
PREMIER OVERVIEW
Industries Automotive
Chemical
Consumer Products
Food & Beverage
Metals
Pulp & Paper
Power
For more info . . .Visit PREMIER’s website at www.premier-system.com
BUSINESS JUSTIFICATION
Lost our internal ProcessLogixTM Champion Support for the Existing Solution increasingly difficult to find. Have a small PlantPAx system in place for Resin Blending.
This in conjunction with ProcessLogix being based on 1756 I/O made the best solution easy to choose.
Had experienced the advantages of built in directed diagnostics. Liked the ability to find trained resources on Rockwell
solutions. ProcessLogix Server stability was becoming a problem. Unsupported Platform from Rockwell Unsupported Hardware/Software (Windows 2000)
BUSINESS JUSTIFICATION
Project justification was on Cost Avoidance. If a failure occurred the MTTR would be significant, increasing production
costs.
On power outages we were having a difficult time recovering due to issues with the ProcessLogix servers.
When process improvements were implemented the labor cost for ProcessLogix integration would be higher than PlantPAx.
MIGRATION STRATEGY
Had existing solution in place for Resin, wanted to build on it. Had an infrastructure that was expanded multiple times
without a well thought out strategy. Had legacy code that needed to be cleaned up. Needed to install the upgrade on a short outage. Operators were already familiar with the Resin system
faceplates and control.
EXISTING INFRASTRUCTURE
FINAL INFRASTRUCTURE
LEGACY CODE MIGRATION
Integrator documented all existing loops. Reviewed code list with production for equipment that was out of
service or provided poor performance. Converted existing code and tuning values. Some sequences were eliminated due to better tools in PlantPAx. Consolidated multiple HMI platforms from other systems into the
new Factory Talk® View SE system. Pulper RSView32 System. Line Drive RSView32 System. Multiple PV+ Applications.
NEEDED TO INSTALL ON A SHORT OUTAGE
Initially targeted a 24 hour production down. Integrator put together a thorough test plan for critical loops
at startup. Actual outage was 36 hours due to other maintenance. Startup went extremely well.
We did have a path back to the ProcessLogix system if we had a catastrophic problem.
We moved two ControlNet Racks to Ethernet due to failing control net cables installed crossing the machine in the basement.
We did have access to the ProcessLogix code if needed to verify operation.
OPERATOR FAMILIARITY
Operators were already comfortable with the HMI due to the existing Resin PlantPAx implementation.
Operator training on the HMI was minimal, screens mimicked the existing ProcessLogix using familiar faceplates.
OPERATOR FAMILIARITY
OPERATOR FAMILIARITY
LEVERAGING PRODUCTION INTELLIGENCE
Chose to use Factory Talk Historian as a replacement for the ProcessLogix Historian.
Chose to use Factory Talk VantagePoint to provide production intelligence to operations management.
Chose to use Factory Talk AssetCentre for Disaster recovery and backup.
Chose to use ACP Thin Manager for HMI clients and engineering station.
LEVERAGING FACTORY TALK HISTORIAN
Used to create trends relating critical process values for a quick overview of production quality.
Used to create ad hock reporting to troubleshoot process problems as they arise.
Used to create required environmental reporting.
Working on Production dashboards for critical KPI’s.
THICK STOCK VS LEVEL
AD HOCK
ENVIRONMENTAL REPORTING
Repository for plant wide control asset programs.
Automated disaster recovery on critical process assets.
FactoryTalk AssetCentre DIRECTORY
FactoryTalk AssetCentre AUDIT LOGS
THIN MANAGER
Tool for managing HMI’s across the facility.
Provides for remote shadowing of operator screens for troubleshooting and diagnostics.
Makes terminal replacement simple.
Simplifies the use of Terminal Services for Factory Talk View HMI servers.
THIN MANAGER TREE
THIN MANAGER SHADOW
SOLUTION
Live Demo of Graphics
MAIN OVERVIEW
LINE DRIVES CONVERTED PV DISPLAY
DIAGNOSTIC EXAMPLES
RESULTS/PATH FORWARD
KPI Screens in FactoryTalk VantagePoint
Converting balance of plant to Ethernet
Automated Reporting of Production
Additional Process Improvements
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
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