Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved. Rockwell Automation TechED 2015 @ROKTechED #ROKTechED

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Scotts Miracle-Gro Improves Reliability and Compliance with Open, Scalable Checkweigher System

Matthew Ackerman

Manufacturing Engineer

Dustin Wilson

Technical Lead

Locally Produced Products

• Turf Builder

• Bonus S

• Weed & Feed

• EZSeed

Original System Background

• Obsolete Windows XP Operating System

• Not scalable within area or across plant(s)

• Not open source code – Could not modify application

– Could not modify reports

– Reoccurring Integrator Labor for system updates

• Application and data reliability issues

Reason For FactoryTalk® • Part of Allen-Bradley® Standardization • FactoryTalk® Connected Components Architecture • Upgrade server hardware

– Virtualization – Operating system compliance – Secure and reliable data storage

• Open source application – Application is able to be modified internally – Reports are able to be modified internally

• Improved Recipe Management • Improve system visibility with Metrics

– OEE – Downtime – Fault tracking

• Phased installation

System Layout

Checkweigher Palletizer Trunkline

System 2Straddle Wrapper

System 2Ring Wrapper

System 2Labeler

System 2Stacker

TrunklineLine 2

TrunklineLine 1

Line 3

How to determine OEE of shared trunkline

Establishing process rates by checkweigher

availability

Marriage of checkweigher data to SAP

Design & Integration

• Network and server structure

– Virtualization

– Application load balancing

– Reports available on Enterprise network (multiple networks)

• Integration with Mettler Toledo Checkweigher

• FactoryTalk® VantagePoint®

– Excelcius live graphics

• FactoryTalk® Metrics

– ReportExpert

– SSRS Reports

• FactoryTalk® Transaction Manager

– HTML & ASP web containers

Requirements Software

FactoryTalk VantagePoint Configuration

• Plant Model created to allow for easy user navigation

• Single user portal to be able to see all production related data

– Live Excelcius graphics

– ReportExport Metrics data

– Custom SSRS report

– Historian trends (future)

• Custom HTML pages used to give “HMI” look and feel

Building Screens HTML Web Container VantagePoint Composite Report

Excelcius Live Graphics & SSRS Reports

FactoryTalk VantagePoint - Checkweigher

• Live graphics give operators real-time data to make production related decisions

• At a glance operators can tell if production is within tolerance

FactoryTalk VantagePoint – Bag Counts

• Live graphics give operators real-time data to make production related decisions

• At a glance operators can tell if production is within tolerance

FactoryTalk VantagePoint - Recipes

• HTML webpage uses FactoryTalk Transaction Manager to store recipe data to SQL database

• SQL Stored Procedure is used to write FTP data to Mettler Toledo Checkweigher on changeover trigger

FactoryTalk Metrics Configuration

• Plant Model

– 10 lines with Checkweigher work cell

• FactoryTalk Plant Schedule

– Used to determine scheduled availability

– 3 shifts every weekday

• Cycle Time

– Ideal cycle time for each part determined by the recipe loaded in PLC

Events and States

• Events

– More than 200 user-defined events

– Events categorized by workcell

• States

– 6-7 workcell states

– 6 overall line states

Custom SSRS Reports • FactoryTalk

VantagePoint and Metrics are built on and seamlessly integrate with SSRS reports

• SSRS reports allow data to be displayed, calculated, and refreshed

ReportExpert • Built-In Reports provide data

right out of the “box”

• Default parameter sets are a quick way to group data

• Custom parameter sets allow the user to drill into data as needed

ReportExpert • Dashboards give an

overview of production

• Tiles group data in an easy to read format

Available Data Production Data KPI’s Event Data State Data Context Data

•Good Part Count •Scrap Part Count •Total Part Count • Scheduled Available Time •Available Time •Running Time •Downtime •Faults •Faulted Time

• OEE% • TEEP • Availability% • Performance% • Quality% • Running% • Good Parts% • Scrap% • Downtime% • Available% • Fault% • Ideal Capacity • Failure Rate • Failure Frequency • MTBF • MTTR

• Event Category • Event Name • Event Reason • Event Starting Value • Event Ending Value • Event Reporting Value • Event Severity • Event Duration • Event Occurrence Count

• State Name • State Duration • State Occurrence Count

• Plant Model • Date/Time • Shift • Shift Instance • Part Id • Five User- Defined Fields

Benefits

• All portions of the system are open source and editable as needed when needed

• Live data allows for on-the-fly adjustments – Fewer over/under bags

• New recipe functions reduce change-over time

• Metrics provides real-time production information

• Future expansion ability to add FactoryTalk Historian for an all-in-one portal

Live Data

Moving Forward

• Implement current Metrics solution to remaining packaging lines

• Apply Six-Sigma to OEE

– Quantify packaging capacity

– Locate bottlenecks and trouble areas

• Custom fault reports to identify deficiencies

• Continuous improvement

– Adjust process rates to match packaging

Questions

www.PhantomTechnical.com Phantom Technical Services, Inc. 111 Outerbelt Street Columbus, Ohio 43213 Phone: (614) 868-9920

www.scottsmiraclegro.com ScottsMiracle-Gro 14101 Industrial Parkway Marysville, OH 43041 Phone: (937) 578-5065

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Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.

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